U.S. patent application number 14/539689 was filed with the patent office on 2015-03-12 for cyclic carbodiimide compound, polyester film, back sheet for solar cell module, and solar cell module.
This patent application is currently assigned to FUJIFILM CORPORATION. The applicant listed for this patent is FUJIFILM Corporation. Invention is credited to Makoto FUKUDA, Seiya SAKURAI.
Application Number | 20150068602 14/539689 |
Document ID | / |
Family ID | 49583581 |
Filed Date | 2015-03-12 |
United States Patent
Application |
20150068602 |
Kind Code |
A1 |
SAKURAI; Seiya ; et
al. |
March 12, 2015 |
CYCLIC CARBODIIMIDE COMPOUND, POLYESTER FILM, BACK SHEET FOR SOLAR
CELL MODULE, AND SOLAR CELL MODULE
Abstract
A polyester film including a cyclic carbodiimide compound
represented by the following Formula (O-1) has good film thickness
uniformity without increase in viscosity. R.sup.1 and R.sup.5
represent an alkyl group, an aryl group, or an alkoxy group;
R.sup.2 to R.sup.4 and R.sup.6 to R.sup.8 represent a hydrogen
atom, an alkyl group, an aryl group, or an alkoxy group; X.sup.1
and X.sup.2 represent a single bond, --O--, --CO--, --S--,
--SO.sub.2--, --NH--, or --CH.sub.2--; and L.sup.1 represents a
divalent linking group. ##STR00001##
Inventors: |
SAKURAI; Seiya; (Shizuoka,
JP) ; FUKUDA; Makoto; (Shizuoka, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FUJIFILM Corporation |
Tokyo |
|
JP |
|
|
Assignee: |
FUJIFILM CORPORATION
Tokyo
JP
|
Family ID: |
49583581 |
Appl. No.: |
14/539689 |
Filed: |
November 12, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/JP2013/062184 |
Apr 25, 2013 |
|
|
|
14539689 |
|
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Current U.S.
Class: |
136/259 ;
525/437; 540/466; 540/469 |
Current CPC
Class: |
C08J 2367/02 20130101;
C08K 5/29 20130101; C07D 498/10 20130101; H01L 31/0203 20130101;
H01L 31/049 20141201; C07D 273/08 20130101; C07D 513/10 20130101;
C08J 5/18 20130101; C08L 67/02 20130101; C07D 285/00 20130101; C08G
63/916 20130101; Y02E 10/50 20130101; B29C 55/12 20130101; C08K
5/29 20130101 |
Class at
Publication: |
136/259 ;
540/469; 540/466; 525/437 |
International
Class: |
H01L 31/0203 20060101
H01L031/0203; C08G 63/91 20060101 C08G063/91; C07D 285/00 20060101
C07D285/00; C07D 513/10 20060101 C07D513/10; C07D 273/08 20060101
C07D273/08; C07D 498/10 20060101 C07D498/10 |
Foreign Application Data
Date |
Code |
Application Number |
May 17, 2012 |
JP |
2012-113227 |
Aug 15, 2012 |
JP |
2012-180258 |
Claims
1. A cyclic carbodiimide compound which is represented by the
following Formula (O-1) or (O-2): ##STR00018## wherein each of
R.sup.1 and R.sup.5 independently represents an alkyl group, an
aryl group, or an alkoxy group; each of R.sup.2 to R.sup.4 and
R.sup.6 to R.sup.8 independently represents a hydrogen atom, an
alkyl group, an aryl group, or an alkoxy group; R.sup.1 to R.sup.8
may be bonded to each other to form a ring; each of X.sup.1 and
X.sup.2 independently represents a single bond, --O--, --CO--,
--S--, --SO.sub.2--, --NH--, or --CH.sub.2--; and L.sup.1
represents a divalent linking group; ##STR00019## wherein each of
R.sup.11, R.sup.15, R.sup.21 and R.sup.25 independently represents
an alkyl group, an aryl group, or an alkoxy group; each of R.sup.12
to R.sup.14, R.sup.16 to R.sup.18, R.sup.22 to R.sup.24, and
R.sup.26 to R.sup.28 independently represents a hydrogen atom, an
alkyl group, an aryl group, or an alkoxy group; R.sup.11 to
R.sup.28 may be bonded to each other to form a ring; each of
X.sup.11, X.sup.12, X.sup.21, and X.sup.22 independently represents
a single bond, --O--, --CO--, --S--, --SO.sub.2--, --NH--, or
--CH.sub.2--; and L.sup.2 represents a tetravalent linking
group.
2. The cyclic carbodiimide compound according to claim 1, wherein
both R.sup.2 and R.sup.6 in Formula (O-1) are hydrogen atoms.
3. The cyclic carbodiimide compound according to claim 1, wherein
each of R.sup.1, R.sup.5, R.sup.11, R.sup.15, R.sup.21 and R.sup.25
in Formulas (O-1) and (O-2) independently represents a secondary or
tertiary alkyl group, or an aryl group.
4. A polyester film, comprising a cyclic carbodiimide compound
which is represented by the following Formula (O-1) or (O-2), and a
polyester: ##STR00020## wherein each of R.sup.1 and R.sup.5
independently represents an alkyl group, an aryl group, or an
alkoxy group; each of R.sup.2 to R.sup.4 and R.sup.6 to R.sup.8
independently represents a hydrogen atom, an alkyl group, an aryl
group, or an alkoxy group; R.sup.1 to R.sup.8 may be bonded to each
other to form a ring; each of X.sup.1 and X.sup.2 independently
represents a single bond, --O--, --CO--, --S--, --SO.sub.2--,
--NH--, or --CH.sub.2--; and L.sup.1 represents a divalent linking
group; ##STR00021## wherein each of R.sup.11, R.sup.15, R.sup.21
and R.sup.25 independently represents an alkyl group, an aryl
group, or an alkoxy group; each of R.sup.12 to R.sup.14, R.sup.16
to R.sup.18, R.sup.22 to R.sup.24, and R.sup.26 to R.sup.28
independently represents a hydrogen atom, an alkyl group, an aryl
group, or an alkoxy group; R.sup.11 to R.sup.28 may be bonded to
each other to form a ring; each of X.sup.11, X.sup.12, X.sup.21 and
X.sup.22 independently represents a single bond, --O--, --CO--,
--S--, --SO.sub.2--, --NH-- or --CH.sub.2--; and L.sup.2 represents
a tetravalent linking group.
5. The polyester film according to claim 4, wherein both R.sup.2
and R.sup.6 in Formula (O-1) are hydrogen atoms.
6. The polyester film according to claim 4, wherein each of
R.sup.1, R.sup.5, R.sup.11, R.sup.15, R.sup.21 and R.sup.25 in
Formulas (O-1) and (O-2) independently represents a secondary or
tertiary alkyl group, or an aryl group.
7. The polyester film according to claim 4, comprising the cyclic
carbodiimide compound in an amount of 0.05% by mass to 5% by mass
relative to 100% by mass of the polyester.
8. The polyester film according to claim 4, wherein a component
derived from carboxylic acid in the polyester is a component
derived from an aromatic dibasic acid or its derivative for forming
an ester.
9. The polyester film according to claim 4 which is biaxially
oriented.
10. A back sheet for a solar cell module having a polyester film
comprising a cyclic carbodiimide compound which is represented by
the following Formula (O-1) or (O-2), and a polyester: ##STR00022##
wherein each of R.sup.1 and R.sup.5 independently represents an
alkyl group, an aryl group, or an alkoxy group; each of R.sup.2 to
R.sup.4 and R.sup.6 to R.sup.8 independently represents a hydrogen
atom, an alkyl group, an aryl group, or an alkoxy group; R.sup.1 to
R.sup.8 may be bonded to each other to form a ring; each of X.sup.1
and X.sup.2 independently represents a single bond, --O--, --CO--,
--S--, --SO.sub.2--, --NH--, or --CH.sub.2--; and L.sup.1
represents a divalent linking group; ##STR00023## wherein each of
R.sup.11, R.sup.15, R.sup.21 and R.sup.25 independently represents
an alkyl group, an aryl group, or an alkoxy group; each of R.sup.12
to R.sup.14, R.sup.16 to R.sup.18, R.sup.22 to R.sup.24, and
R.sup.26 to R.sup.28 independently represents a hydrogen atom, an
alkyl group, an aryl group, or an alkoxy group; R.sup.11 to
R.sup.28 may be bonded to each other to form a ring; each of
X.sup.11, X.sup.12, X.sup.21 and X.sup.22 independently represents
a single bond, --O--, --CO--, --S--, --SO.sub.2--, --NH-- or
--CH.sub.2--; and L.sup.2 represents a tetravalent linking
group.
11. A solar cell module having a back sheet for a solar cell
module, wherein the solar cell module has a polyester film
comprising a cyclic carbodiimide compound which is represented by
the following Formula (O-1) or (O-2), and a polyester: ##STR00024##
wherein each of R.sup.1 and R.sup.5 independently represents an
alkyl group, an aryl group, or an alkoxy group; each of R.sup.2 to
R.sup.4 and R.sup.6 to R.sup.8 independently represents a hydrogen
atom, an alkyl group, an aryl group, or an alkoxy group; R.sup.1 to
R.sup.8 may be bonded to each other to form a ring; each of X.sup.1
and X.sup.2 independently represents a single bond, --O--, --CO--,
--S--, --SO.sub.2--, --NH--, or --CH.sub.2--; and L.sup.1
represents a divalent linking group; ##STR00025## wherein each of
R.sup.11, R.sup.15, R.sup.21 and R.sup.25 independently represents
an alkyl group, an aryl group, or an alkoxy group; each of R.sup.12
to R.sup.14, R.sup.16 to R.sup.18, R.sup.22 to R.sup.24, and
R.sup.26 to R.sup.28 independently represents a hydrogen atom, an
alkyl group, an aryl group, or an alkoxy group; R.sup.11 to
R.sup.28 may be bonded to each other to form a ring; each of
X.sup.11, X.sup.12, X.sup.21 and X.sup.22 independently represents
a single bond, --O--, --CO--, --S--, --SO.sub.2--, --NH-- or
--CH.sub.2--; and L.sup.2 represents a tetravalent linking group.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of
International Application No. PCT/JP2013/062184, filed Apr. 25,
2013, which in turn claims the benefit of priority from Japanese
Application No. 2012-113227, filed on May 17, 2012, and Japanese
Application No. 2012-180258, filed on Aug. 15, 2012, the
disclosures of which Applications are incorporated by reference
herein in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a cyclic carbodiimide
compound, a polyester film using the cyclic carbodiimide compound,
a back sheet for a solar cell module, and a solar cell module.
[0004] 2. Background Art
[0005] A solar cell module generally has a laminate structure in
which a transparent filling material (which is hereinafter also
referred to as a sealing material)/a photovoltaic cell/a sealing
material/a back sheet (which is hereinafter also referred to as BS)
are laminated in this order on a glass or front sheet on the
light-receiving surface side to which sunlight is incident.
Specifically, the photovoltaic cell is generally embedded with a
resin (sealing material) such as EVA (an ethylene-vinyl acetate
copolymer) and the like, and protective sheet for a solar cell is
adhered thereto. Further, as this protective sheet for a solar
cell, a polyester film, in particular, a polyethylene terephthalate
(which is hereinafter also referred to as PET) film has been
used.
[0006] However, the protective sheet for a solar cell, above all, a
back sheet (BS) for a solar cell module, which becomes in
particular an outermost layer, is considered to be under an
environment exposed to weather outdoor for a long period of time,
and therefore, excellent weather resistance is required.
[0007] Here, a polyester film such as PET and the like, which is
also used as a back sheet for a solar cell module has excellent
heat resistance, mechanical characteristics, chemical resistance,
and the like, and therefore, is widely used industrially. However,
it still needs to be improved. As the technology for improving the
characteristics of the polyester film in this manner, it is known
that by reacting a carbodiimide compound with a terminal carboxyl
group of polyester, hydrolysis resistance is improved, and
applications to a PET film for a solar cell back sheet or the like
have been studied. However, since a general carbodiimide compound
generates isocyanate having a low molecular weight by reaction with
a terminal carboxyl group of polyester, irritant gases volatilize
in the production step, and thus, it has become a problem.
[0008] In recent years, a cyclic carbodiimide compound is proposed,
and it is reported that when producing a film in a melt state by
adding polyester, it is possible to suppress isocyanate gas (refer
to Patent Literatures 1 and 2). In Patent Literatures 1 and 2, it
is described that since isocyanate which is generated by a reaction
with a terminal carboxyl group of polyester is linked to a terminal
of polyester, the cyclic carbodiimide can suppress volatilization
of isocyanate gas.
CITATION LIST
Patent Literatures
[0009] Patent Literature 1: WO 2010/071211 [0010] Patent
Literature2: JP-A-2011-258641
SUMMARY OF INVENTION
[0011] On the other hand, though a polyester film used in a solar
cell module is required to have a high partial discharge voltage,
with the increase of a required power generation output, when film
production stability is poor and a portion having a thin film
thickness partially exists, the partial discharge voltage is
significantly lowered. For this reason, a polyester film used in a
solar cell module is required to have the film production
stability, that is, film thickness uniformity.
[0012] However, when the present inventors of the present invention
produced a biaxially oriented polyester film by using the cyclic
carbodiimide described in Patent Literatures 1 and 2, it was found
that an isocyanate group linked to a polyester terminal has high
reactivity with a hydroxyl group terminal of polyester, and as long
as a known cyclic carbodiimide is used, viscosity of the polyester
is significantly increased, and thus the polyester is difficult to
use.
[0013] The present invention has been made taking this situation
into consideration, and it is a problem to be solved by the present
invention to provide a polyester film which does not contain
isocyanate having a low molecular weight, and has good film
thickness uniformity without increase in viscosity. In addition, it
is possible to provide a cyclic carbodiimide compound which can be
used for the production of the polyester film as described above,
can suppress increase in viscosity, and suppress generation of
isocyanate gas during the film production.
[0014] The inventors of the present invention have found that by
using a compound which includes a cyclic structure in which both
first nitrogen and second nitrogen in a carbodiimide group are
adjacent to arylene groups, and the arylene groups are bonded to
each other by a bonding group, and has a specific bulky substituent
at an ortho-position with respect to the carbodiimide group in the
arylene group, it is possible to suppress generation of isocyanate
gas, and by suppressing the reaction between isocyanate linked to
the terminal of the polyester and a hydroxyl group terminal of the
polyester, it is possible to suppress increase in viscosity during
the film production, thereby providing the present invention having
the following configurations.
[0015] [1] A cyclic carbodiimide compound which is represented by
the following Formula (O-1) or (O-2).
##STR00002##
[0016] In Formula (O-1), each of R.sup.4 and R.sup.5 independently
represents an alkyl group, an aryl group, or an alkoxy group. Each
of R.sup.2 to R.sup.4 and R.sup.6 to R.sup.8 independently
represents a hydrogen atom, an alkyl group, an aryl group, or an
alkoxy group. R.sup.1 to R.sup.8 may be bonded to each other to
form a ring. Each of X.sup.1 and X.sup.2 independently represents a
single bond, --O--, --CO--, --S--, --SO.sub.2--, --NH--, or
--CH.sub.2--. L.sup.1 represents a divalent linking group.
##STR00003##
[0017] In Formula (O-2), each of R.sup.11, R.sup.15, R.sup.21, and
R.sup.25 independently represents an alkyl group, an aryl group, or
an alkoxy group. Each of R.sup.12 to R.sup.14, R.sup.16 to
R.sup.18, R.sup.22 to R.sup.24, and R.sup.26 to R.sup.28
independently represents a hydrogen atom, an alkyl group, an aryl
group, or an alkoxy group. R.sup.11 to R.sup.28 may be bonded to
each other to form a ring. Each of X.sup.11, X.sup.12, X.sup.21,
and X.sup.22 independently represents a single bond, --O--, --CO--,
--S--, --SO.sub.2--, --NH--, or --CH.sub.2--. L.sup.2 represents a
tetravalent linking group.
[0018] [2] The cyclic carbodiimide compound according to [1], in
which both R.sup.2 and R.sup.6 in Formula (O-1) are preferably
hydrogen atoms.
[0019] [3] The cyclic carbodiimide compound according to [1] or
[2], in which each of R.sup.1, R.sup.5, R.sup.11, R.sup.15,
R.sup.21, and R.sup.25 in Formulas (O-1) and (O-2) preferably
independently represents a secondary or tertiary alkyl group, or an
aryl group.
[0020] [4] A polyester film including the cyclic carbodiimide
compound which is represented by the following Formula (O-1) or
(O-2) and polyester.
##STR00004##
[0021] In Formula (O-1), each of R.sup.4 and R.sup.5 independently
represents an alkyl group, an aryl group, or an alkoxy group. Each
of R.sup.2 to R.sup.4 and R.sup.6 to R.sup.8 independently
represents a hydrogen atom, an alkyl group, an aryl group, or an
alkoxy group. R.sup.1 to R.sup.8 may be bonded to each other to
form a ring. Each of X.sup.1 and X.sup.2 independently represents a
single bond, --O--, --CO--, --S--, --SO.sub.2--, --NH--, or
--CH.sub.2--. L.sup.1 represents a divalent linking group.
##STR00005##
[0022] In Formula (0-2), each of R.sup.11, R.sup.15, R.sup.21, and
R.sup.25 independently represents an alkyl group, an aryl group, or
an alkoxy group. Each of R.sup.12 to R.sup.14, R.sup.16 to
R.sup.18, R.sup.22 to R.sup.24, and R.sup.26 to R.sup.28
independently represents a hydrogen atom, an alkyl group, an aryl
group, or an alkoxy group. R.sup.11 to R.sup.28 may be bonded to
each other to form a ring. Each of X.sup.11, X.sup.12, X.sup.21,
and X.sup.22 independently represents a single bond, --O--, --CO--,
--S--, --SO.sub.2--, --NH--, or --CH.sub.2--. L.sup.2 represents a
tetravalent linking group.
[0023] [5] The polyester film according to [4], in which both
R.sup.2 and R.sup.6 in Formula (O-1) are preferably hydrogen
atoms.
[0024] [6] The polyester film according to [4] or [5], in which
each of R.sup.1, R.sup.5, R.sup.11, R.sup.15, R.sup.21, and
R.sup.25 in Formulas (O-1) and (O-2) preferably independently
represents a secondary or tertiary alkyl group, or an aryl
group.
[0025] [7] The polyester film according to any one of [4] to [6]
including the cyclic carbodiimide compound in an amount of 0.05% by
mass to 5% by mass relative to 100% by mass of the polyester.
[0026] [8] The polyester film according to any one of [4] to [7],
in which a component derived from carboxylic acid in the polyester
is preferably a component derived from an aromatic dibasic acid or
its derivative for forming an ester.
[0027] [9] The polyester film according to any one of [4] to [8],
which is preferably biaxially oriented.
[0028] [10] A back sheet for a solar cell module using the
polyester film according to any one of [4] to [9].
[0029] [11] A solar cell module using the back sheet for a solar
cell module according to [10].
[0030] According to the present invention, it is possible to
provide a polyester film which does not include isocyanate having a
low molecular weight, and has good film thickness uniformity
without increase in viscosity. In addition, it is possible to
provide a cyclic carbodiimide compound which can be used for the
production of the polyester film of the present invention as
described above, can suppress increase in viscosity, and suppress
generation of isocyanate gas during the film production.
DESCRIPTION OF EMBODIMENTS
[0031] Hereinafter, the polyester film, the back sheet for a solar
cell module, and the solar cell module of the present invention
will be described in detail.
[0032] The description of the constitutive elements as described
below is based on typical embodiments of the present invention, but
the present invention should not be limited thereto. Further, the
numerical range expressed by the wording "(a lower limit) to (an
upper limit)" means a range that falls between the former number
indicating the lower limit of the range and the latter number
indicating the upper limit thereof.
[0033] Moreover, as isocyanate having a low molecular weight,
isocyanate having a molecular weight of 300 or less can be
exemplified, however, the present invention is not limited to the
range of the molecular weight.
[0034] [Polyester Film]
[0035] The polyester film of the present invention (hereinafter,
also referred to the film of the present invention) includes the
cyclic carbodiimide compound which is represented by the following
Formula (O-1) or (O-2) and polyester.
##STR00006##
[0036] In Formula (O-1), each of R.sup.4 and R.sup.5 independently
represents an alkyl group, an aryl group, or an alkoxy group. Each
of R.sup.2 to R.sup.4 and R.sup.6 to R.sup.8 independently
represents a hydrogen atom, an alkyl group, an aryl group, or an
alkoxy group. R.sup.1 to R.sup.8 may be bonded to each other to
form a ring. Each of X.sup.1 and X.sup.2 independently represents a
single bond, --O--, --CO--, --S--, --SO.sub.2--, --NH--, or
--CH.sub.2--. L.sup.1 represents a divalent linking group.
##STR00007##
[0037] In Formula (0-2), each of R.sup.11, R.sup.15, R.sup.21, and
R.sup.25 independently represents an alkyl group, an aryl group, or
an alkoxy group. Each of R.sup.12 to R.sup.14, R.sup.16 to
R.sup.18, R.sup.22 to R.sup.24, and R.sup.26 to R.sup.28
independently represents a hydrogen atom, an alkyl group, an aryl
group, or an alkoxy group. R.sup.11 to R.sup.28 may be bonded to
each other to form a ring. Each of X.sup.11, X.sup.12, X.sup.21,
and X.sup.22 independently represents a single bond, --O--, --CO--,
--S--, --SO.sub.2--, --NH--, or --CH.sub.2--. L.sup.2 represents a
tetravalent linking group.
[0038] It is also not to be bound by any theory, it is assumed that
when melt-extruding a composition including polyester and a
carbodiimide compound at about 280.degree. C., for example, when
using cyclic aromatic carbodiimide known in the art as a PET
terminal blocking agent, (1) a reaction between carbodiimide group
and PET-COOH and (2) a reaction between an isocyanate group and
PET-OH take place as the following reaction scheme, increase in
viscosity occurs, and gel is generated.
##STR00008## ##STR00009##
[0039] The increase in viscosity and the generation of gel
according to the above-described reaction scheme become factors
that adversely affect the film thickness uniformity of the obtained
polyester film.
[0040] In contrast, it was found that by producing a polyester film
using a cyclic carbodiimide compound having a specific bulky
substituent at an ortho-position with respect to a carbodiimide
group of an arylene group adjacent to the carbodiimide, the
polyester film having the configuration of the present invention
can suppress the reaction with PET-OH in the above reaction scheme,
and it is possible to suppress adverse effects on the film
thickness uniformity when adding a cyclic carbodiimide compound. As
a result, it is possible to provide a polyester film which does not
include isocyanate having a low molecular weight, and has good film
thickness uniformity without increase in viscosity. In addition, in
a case where isocyanate gas described in the production step is
included in the polyester film, there is a problem in that
adhesiveness to the functional layer after wet heat aging when used
in a back sheet for a solar cell module deteriorates, however, it
is possible to solve such a problem by using the cyclic
carbodiimide of the present invention.
[0041] Hereinafter, a material used in the polyester film of the
present invention including the cyclic carbodiimide compound of the
present invention, the configuration and characteristics of the
polyester film of the present invention, and a method for producing
the polyester film of the present invention will be described,
however, the present invention is not limited to the following
embodiments.
[0042] Moreover, within a range not interfering with the effects of
the present invention, various additives, for example, a
carbodiimidization catalyst, a compatibilizer, a plasticizer, a
weathering agent, an antioxidant, a thermal stabilizer, a
lubricant, an antistatic agent, a brightener, a colorant, a
conductive agent, an ultraviolet absorber, a flame retardant, a
flame retardant auxiliary agent, a pigment, a dye, or the like may
be added to the polyester film of the present invention.
[0043] <Material Used in Polyester Film>
[0044] (Polyester)
[0045] The polyester film of the present invention includes
polyester. The polyester is not particularly limited, and the
preferable embodiments will be described below.
[0046] The intrinsic viscosity (IV) of the polyester is preferably
0.5 dl/g to 0.9 dl/g from the viewpoint of achieving both
hydrolysis resistance and film thickness uniformity. By setting the
intrinsic viscosity of the polyester to such a range, it is
possible reduce the number of polyester terminals, that is, the
crosslinking point, and it is possible to suppress gel
formation.
[0047] The intrinsic viscosity is preferably 0.55 dl/g to 0.85
dl/g, and particularly preferably 0.6 dl/g to 0.84 dl/g from the
viewpoint of suppressing the gel formation, achieving both
hydrolysis resistance and film thickness uniformity, setting the
intrinsic viscosity after film formation in the preferable range as
described later, and stirrability at the time of synthesizing with
a carbodiimide described later.
[0048] For the intrinsic viscosity (IV) of polyester (IV), in a
case where polyester used during the film production is 2 or more
types (for example, a case of using the retrieved polyester of
JP-A-2011-256337 or the like), the intrinsic viscosity of polyester
obtained by mixing all polyester preferably satisfies the above
range.
[0049] For the intrinsic viscosity (IV) of polyester, polyester is
dissolved in ortho-chlorophenol, and from the solution viscosity
measured at 25.degree. C., the intrinsic viscosity [.eta.] is
obtained by the following equation.
.eta..sub.sp/C=[.eta.]+K[.eta.].sup.2C
[0050] Here, .eta..sub.sp is (solution viscosity/solvent viscosity)
-1, C is the dissolved polymer weight per 100 ml of solvent (1
g/100 ml in this measurement), K is Huggins constant (0.343), and
the solution viscosity and the solvent viscosity are measured using
an Ostwald viscometer.
[0051] The polyester is preferably saturated polyester.
[0052] By using such saturated polyester, it is possible to obtain
an excellent polyester film compared to the film using unsaturated
polyester from the viewpoint of dynamic strength.
[0053] The polyester has a --COO-- bond or a --OCO-- bond in the
middle of the polymer. In addition, the terminal group of the
polyester is preferably a linear saturated polyester synthesized
from an aromatic dibasic acid or its derivative capable of forming
an ester, a diol or an derivative for forming an ester thereof as
an OH group, a COOH group, or a protected group thereof (an
OR.sup.X group, a COOR.sup.X group (R.sup.X is any substituent such
as an alkyl group). As the linear saturated polyester, for example,
those described in 2009-155479 or JP-A-2010-235824 can be suitably
used.
[0054] Specific examples of the linear saturated polyester include
polyethylene terephthalate (PET), polyethylene isophthalate,
polybutylene terephthalate, poly(1,4-cyclohexylenedimethylene
terephthalate), polyethylene-2,6-naphthalate, and among these,
polyethylene terephthalate or polyethylene-2,6-naphthalate is
particularly preferable, and polyethylene terephthalate is more
particularly preferable from the viewpoint of the balance between
the mechanical properties and the cost. Moreover, whereas a film of
polyethylene-2,6-naphthalate or polybutylene terephthalate is
produced in a melt state by heating to 230.degree. C. or higher
during the film production, a film of PET is produced in a melt
state by heating to 250.degree. C. or higher, and thus isocyanate
is further easily generated, and in the polyester film of the
present invention, it is possible to reduce the residual amount of
isocyanate even in a case where the polyester (A) is PET.
[0055] The polyester may be a homopolymer or a copolymer.
Furthermore, it may be a blend of the polyester with a small amount
of any other type of resin, for example, polyimide, or the like. In
addition, it is also possible to use a crystalline polyester which
can form anisotropy during the melting as the polyester.
[0056] The terminal carboxyl group content in the polyester (the
carboxylic acid value of the polyester, hereinafter, referred to as
AV) is preferably 25 eq/ton or less, more preferably 20 eq/ton or
less, particularly preferably 16 eq/ton or less, and more
particularly preferably 15 eq/ton or less with respect to the
polyester. If the carboxyl group content is 25 eq/ton or less, the
hydrolysis resistance of polyester film and heat resistance by
combination with the cyclic carbodiimide compound are maintained,
and thus, reduction of strength at a time of wet heat aging can be
suppressed low. The lower limit of the terminal carboxyl group
content is desirably 10 eq/ton or greater from the viewpoint of
keeping the adhesiveness (adhesive property) among layers (for
example, a white layer) formed when the polyester film of the
present invention is used as the back sheet for a solar cell
module. The terminal carboxyl group content in the polyester can be
adjusted by the kind of a polymerization catalyst, the
polymerization time, or the film formation conditions (the film
formation temperature and time). The carboxyl group content can be
measured by a titration method according to the method described in
H. A. Pohl, Anal. Chem. 26 (1954) 2145. Specifically, a polyester
is dissolved in benzyl alcohol at 205.degree. C. and a phenol red
indicator is added. Then, titration is performed with a
water/methanol/benzyl alcohol solution of sodium hydroxide, and
from the titration amount, the carboxylic acid value (eq/ton) can
be calculated.
[0057] The terminal hydroxyl group content in the polyester is
preferably 120 eq/ton or less, and more preferably 90 eq/ton or
less, with respect to the polyester. If the hydroxyl group content
is 120 eq/ton or less, the reaction between cyclic carbodiimide
having a bulky functional group at a specific position described
later and the hydroxyl group is suppressed, and thus, the reaction
with a carboxyl group is preferentially undergone, which can
further reduce the carboxylic acid value. The lower limit of the
hydroxyl group content is desirably 20 eq/ton from the viewpoint of
adhesiveness with an upper layer. The hydroxyl group content in the
polyester can be adjusted by the kind of a polymerization catalyst,
the polymerization time, or the film formation conditions (the film
formation temperature and time). For the terminal hydroxyl group
content, a value measured by .sup.1H-NMR, using a deuterated
hexafluoroisopropanol solvent, can be used.
[0058] For the molecular weight of the polyester, the weight
average molecular weight (Mw) is preferably 5,000 to 30,000, more
preferably 8,000 to 26,000, and particularly preferably 12,000 to
24,000 from the viewpoint of heat resistance and viscosity. As the
weight average molecular weight of the polyester, a value in terms
of polymethyl methacrylate (PMMA), measured by gel permeation
chromatography (GPC) using hexafluoroisopropanol as a solvent, can
be used.
[0059] The polyester can be synthesized according to a known
method. For example, polyester can be synthesized according to a
known polycondensation method, a ring-opening polymerization
method, or the like, which can be applied to any one of the
reactions by transesterification reaction and direct
polymerization.
[0060] In a case where the polyester used in the present invention
is a polymer or copolymer, obtained by the condensation reaction of
an aromatic dibasic acid or its derivative capable of forming an
ester with a diol or an derivative for forming an ester thereof as
a main components, the polyester can be produced by subjecting an
aromatic dibasic acid or its derivative capable of forming an ester
thereof, and a diol or an derivative for forming an ester thereof
to esterification reaction or transesterification reaction, and
then to polycondensation reaction. Further, by selecting the raw
material or the reaction condition, the carboxylic acid value or
the intrinsic viscosity of the polyester can be controlled.
Further, in order to perform the esterification or
transesterification reaction and the polycondensation reaction
effectively, it is preferable to add a polymerization catalyst
during these reactions.
[0061] As a polymerization catalyst in the polymerization of the
polyester, an Sb-based, Ge-based, or Ti-based compound is
preferably used from the viewpoint of inhibiting the carboxyl group
content to a predetermined range or less. Among these, a Ti-based
compound is particularly preferable. In the case of using a
Ti-based compound, the Ti-based compound is used as the catalyst in
the range of the amount of 1 ppm to 30 ppm, and more preferably 3
ppm to 15 ppm to perform polymerization. If the proportion of the
Ti-based compound is within the range, it is possible to adjust the
terminal carboxyl groups to fall within the range as described
below, and it is also possible to keep the hydrolysis resistance of
the polymer substrate low.
[0062] In the synthesis of the polyester using a Ti-based compound,
for example, the methods described in JP-B-8-301198, Japanese
Patent Nos. 2543624, 3335683, 3717380, 3897756, 3962226, 3979866,
3996871, 4000867, 4053837, 4127119, 4134710, 4159154, 4269704,
4313538, or the like may be applied.
[0063] Preferably, the polyester is one subjected to solid-phase
polymerization after polymerization. This can result in the
preferable carboxylic acid value. The solid-phase polymerization
may be in a continuous method (where the resin is filled in a
tower, gradually circulated therein with heating for a
predetermined period of time, and then discharged) or in a batch
method (where the resin is put into a container and heated therein
for a predetermined period of time). Specifically, the methods
described in Japanese Patents 2621563, 3121876, 3136774, 3603585,
3616522, 3617340, 3680523, 3717392, 4167159, or the like may be
applied to the solid-phase polymerization.
[0064] The temperature of the solid-phase polymerization is
preferably 170.degree. C. to 240.degree. C., more preferably from
180.degree. C. to 230.degree. C., and even more preferably
190.degree. C. to 220.degree. C. The time of the solid-phase
polymerization is preferably 5 hours to 100 hours, more preferably
10 hours to 75 hours, and even more preferably 15 hours to 50
hours. The solid-phase polymerization is preferably performed in
vacuum or in a nitrogen atmosphere.
[0065] (Cyclic Carbodiimide Compound)
[0066] The polyester film of the present invention includes the
cyclic carbodiimide compound (hereinafter, also referred to as the
cyclic carbodiimide compound of the present invention) which is
represented by Formula (O-1) or (O-2).
[0067] Hereinafter, the preferable structure of the cyclic
carbodiimide compound of the present invention will be described in
order of Formulas (O-1) and (O-2).
[0068] First, the cyclic carbodiimide compound which is represented
by Formula (O-1) will be described.
##STR00010##
[0069] In Formula (O-1), each of R.sup.4 and R.sup.5 independently
represents an alkyl group, an aryl group, or an alkoxy group. Each
of R.sup.2 to R.sup.4 and R.sup.6 to R.sup.8 independently
represents a hydrogen atom, an alkyl group, an aryl group, or an
alkoxy group. R.sup.1 to R.sup.8 may be bonded to each other to
form a ring. Each of X.sup.1 and X.sup.2 independently represents a
single bond, --O--, --CO--, --S--, --SO.sub.2--, --NH--, or
--CH.sub.2--. L.sup.1 represents a divalent linking group.
[0070] In Formula (O-1), each of R.sup.1 and R.sup.5 independently
represents an alkyl group, an aryl group, or an alkoxy group,
preferably represents an alkyl group or an aryl group, more
preferably represents a secondary or tertiary alkyl group, or an
aryl group from the viewpoint of suppressing the reaction of
isocyanate linked to the terminal of polyester and the hydroxyl
group terminal of polyester and suppressing increase in viscosity,
and particularly preferably represent a secondary alkyl group.
[0071] The alkyl group which is represented by R.sup.1 or R.sup.5
is preferably an alkyl group having 1 to 20 carbon atoms, more
preferably an alkyl group having 1 to 12 carbon atoms, and
particularly preferably an alkyl group having 2 to 6 carbon atoms.
The alkyl group which is represented by R.sup.1 or R.sup.5 may be a
linear alkyl group, a branched alkyl group, or a cyclic alkyl
group, however, a branched alkyl group or a cyclic alkyl group is
preferable from the viewpoint of suppressing the reaction of
isocyanate linked to the terminal of polyester and the hydroxyl
group terminal of polyester and suppressing increase in viscosity.
The alkyl group which is represented by R.sup.1 or R.sup.5 is
preferably a secondary or tertiary alkyl group, and more preferably
a secondary alkyl group. Examples of the alkyl group which is
represented by R.sup.1 or R.sup.2 include a methyl group, an ethyl
group, an n-propyl group, a sec-propyl group, an iso-propyl group,
an n-butyl group, a tert-butyl group, a sec-butyl group, an
iso-butyl group, an n-pentyl group, a sec-pentyl group, an
iso-pentyl group, an n-hexyl group, a sec-hexyl group, an iso-hexyl
group, and a cyclohexyl group, and among these, an iso-propyl
group, a tert-butyl group, an iso-butyl group, an iso-pentyl group,
an iso-hexyl group, and a cyclohexyl group are preferable, an
iso-propyl group, a cyclohexyl group, and a tert-butyl group are
more preferable, and an iso-propyl group and a cyclohexyl group are
particularly preferable.
[0072] The alkyl group which is represented by R.sup.1 or R.sup.5
may further have a substituent, and the substituent is not
particularly limited. However, the alkyl group which is represented
by R.sup.1 or R.sup.5 preferably does not further have a
substituent from the viewpoint of reactivity with carboxylic
acid.
[0073] The aryl group which is represented by R.sup.1 or R.sup.5 is
preferably an aryl group having 6 to 20 carbon atoms, more
preferably an aryl group having 6 to 12 carbon atoms, and
particularly preferably an aryl group having 6 carbon atoms. The
aryl group which is represented by R.sup.1 or R.sup.5 may be an
aryl group formed by condensation of R.sup.1 and R.sup.2 or R.sup.5
and R.sup.6, and each of R.sup.1 and R.sup.5 preferably does not
form a ring by condensation with R.sup.2 or R.sup.6. Examples of
the aryl group which is represented by R.sup.1 or R.sup.5 include a
phenyl group and a naphthyl group or the like, and among these, a
naphthyl group is more preferable.
[0074] The aryl group which is represented by R.sup.1 or R.sup.5
may further have a substituent, and the substituent is not
particularly limited. However, the aryl group which is represented
by R.sup.1 or R.sup.5 preferably does not further have a
substituent from the viewpoint of reactivity with carboxylic
acid.
[0075] The alkoxy group which is represented by R.sup.1 or R.sup.5
is preferably an alkoxy group having 1 to 20 carbon atoms, more
preferably an alkoxy group having 1 to 12 carbon atoms, and
particularly preferably an alkoxy group having 2 to 6 carbon atoms.
The alkoxy group which is represented by R.sup.1 or R.sup.5 may be
a linear alkoxy group, a branched alkoxy group, or a cyclic alkoxy
group, however, a branched alkoxy group or a cyclic alkoxy group is
preferable from the viewpoint of suppressing the reaction of
isocyanate linked to the terminal of polyester and the hydroxyl
group terminal of polyester and suppressing increase in viscosity.
Preferable example of an alkoxy group which is represented by
R.sup.1 or R.sup.5 is a group in which --O-- is linked to the
terminal of an alkyl group which is represented by R.sup.1 or
R.sup.5, and preferable range is also the same as that of a group
in which --O-- is linked to the terminal of a preferable alkyl
group which is represented by R.sup.1 or R.sup.5.
[0076] The alkoxy group which is represented by R.sup.1 or R.sup.5
may further have a substituent, and the substituent is not
particularly limited. However, the alkoxy group which is
represented by R.sup.1 or R.sup.5 preferably does not further have
a substituent from the viewpoint of reactivity with carboxylic
acid.
[0077] R.sup.1 and R.sup.5 may be the same as or different from
each other, and are preferably the same from the viewpoint of
cost.
[0078] In Formula (O-1), each of R.sup.2 to R.sup.4 and R.sup.6 to
R.sup.8 independently represents a hydrogen atom, an alkyl group,
an aryl group, or an alkoxy group, and a hydrogen atom, an alkyl
group having 1 to 20 carbon atoms, and an alkoxy group having 1 to
20 carbon atoms are preferable, a hydrogen atom and, an alkyl group
having 1 to 6 carbon atoms are more preferable, and a hydrogen atom
is particularly preferable.
[0079] The alkyl group, the aryl group, or the alkoxy group which
is represented by R.sup.2 to R.sup.4 or R.sup.6 to R.sup.8 may
further have a substituent, and the substituent is not particularly
limited.
[0080] In the cyclic carbodiimide compound of the present
invention, both R.sup.2 and R.sup.6 in Formula (O-1) are preferably
hydrogen atoms from the viewpoint of ease of introducing a bulky
substituent to R.sup.1 and R.sup.5. Here, in p. 15 and p. 14 of
WO2010/071211, a compound in which a site (meta-position with
respect to the carbodiimide group) corresponding to R.sup.2 or
R.sup.6 in Formula (O-1) are substituted with an alkyl group or an
aryl group is illustrated, however, these compounds cannot suppress
the reaction of isocyanate linked to the terminal of polyester and
the hydroxyl group terminal of polyester, and introduction of a
substituent to a site (ortho-position with respect to the
carbodiimide group) corresponding to R.sup.2 or R.sup.6 in Formula
(O-1) is difficult.
[0081] In Formula (O-1), R.sup.1 to R.sup.8 may be bonded to each
other to form a ring. The ring formed at this time is not
particularly limited, and aromatic ring is preferable. For example,
two or more of R.sup.1 to R.sup.4 may be bonded to each other to
form a condensed ring, and may form an arylene group or a
heteroarylene group having 10 or more carbon atoms with a benzene
ring in which R.sup.1 to R.sup.4 are substituted. As the arylene
group having 10 or more carbon atoms formed at this time, an
aromatic group having 10 to 15 carbon atoms such as a
naphthalenediyl group or the like can be exemplified.
[0082] In the same manner, for example, two or more of R.sup.5 to
R.sup.8 may be bonded to each other to form a condensed ring,
R.sup.5 to R.sup.8 may form an arylene group or a heteroarylene
group having 10 or more carbon atoms with a benzene ring in which
R.sup.5 to R.sup.8 are substituted and the preferable range at this
time is the same as the preferable range when forming an arylene
group or a heteroarylene group having 10 or more carbon atoms with
a benzene ring in which R.sup.1 to R.sup.4 are substituted.
[0083] However, in the cyclic carbodiimide compound of the present
invention, R.sup.1 to R.sup.8 in Formula (O-1) preferably does not
form a ring by bonding to each other.
[0084] In Formula (O-1), each of X.sup.1 and X.sup.2 independently
represents at least one type selected from a single bond, --O--,
--CO--, --S--, --SO.sub.2--, --NH--, or --CH.sub.2--, and among
these, preferably --O--, --CO--, --S--, --SO.sub.2--, or --NH--,
more preferable --O--, or --S-- from the viewpoint of ease of
synthesis.
[0085] In Formula (O-1), L.sup.1 represents a divalent linking
group, and is preferably a divalent aliphatic group having 1 to 20
carbon atoms, a divalent alicyclic group having 3 to 20 carbon
atoms, a divalent aromatic group having 5 to 15 carbon atoms which
may include a heteroatom or a substituent, respectively, or a
combination of these, and more preferably a divalent aliphatic
group having 1 to 20 carbon atoms.
[0086] As a divalent aliphatic group which is represented by
L.sup.1, an alkylene group having 1 to 20 carbon atoms can be
exemplified. Examples of the alkylene group having 1 to 20 carbon
atoms include a methylene group, an ethylene group, a propylene
group, a butylene group, a pentylene group, a hexylene group, a
heptylene group, an octylene group, a nonylene group, a decylene
group, a dodecylene group, and hexadecylene group, and a methylene
group, an ethylene group, and a propylene group is more preferable,
and an ethylene group is particularly preferable. These aliphatic
groups may be substituted. Examples of the substituents include an
alkyl group having 1 to 20 carbon atoms, an aryl group having 6 to
15 carbon atoms, a halogen atom, a nitro group, an amide group, a
hydroxyl group, an ester group, an ether group, and an aldehyde
group.
[0087] As a divalent alicyclic group which is represented by
L.sup.1, a cycloalkylene group having 3 to 20 carbon atoms can be
exemplified. Examples of the cycloalkylene group having 3 to 20
carbon atoms include a cyclopropylene group, a cyclobutylene group,
a cyclopentylene group, a cyclohexylene group, a cycloheptylene
group, a cyclooctylene group, a cyclononylene group, a
cyclodecylene group, a cyclododecylene group, and a
cyclohexadecylene group. These alicyclic groups may be substituted.
Examples of the substituents include an alkyl group having 1 to 20
carbon atoms, an aryl group having 6 to 15 carbon atoms, a halogen
atom, a nitro group, an amide group, a hydroxyl group, an ester
group, an ether group, and an aldehyde group.
[0088] As a divalent aromatic group which is represented by
L.sup.1, an arylene group having 5 to 15 carbon atoms which may
have a heterocyclic structure by including a heteroatom can be
exemplified. Examples of the arylene group having 5 to 15 carbon
atoms include a phenylene group and a naphthalenediyl group. These
aromatic groups may be substituted. Examples of the substituents
include an alkyl group having 1 to 20 carbon atoms, an aryl group
having 6 to 15 carbon atoms, a halogen atom, a nitro group, an
amide group, a hydroxyl group, an ester group, an ether group, and
an aldehyde group.
[0089] In Formula (O-1), the number of atoms in a cyclic structure
which includes a carbodiimide group is preferably 8 to 50, more
preferably 10 to 30, still more preferably 10 to 20, and
particularly preferably 10 to 15.
[0090] Here, the number of atoms in the cyclic structure which
includes a carbodiimide group means the number of atoms which
directly configure the cyclic structure which includes a
carbodiimide group, and for example, when the cyclic structure is
an eight-membered ring, the number of atoms is 8, and when the
cyclic structure is a fifty-membered ring, the number of atoms is
50. This is because in a case where the number of atoms in the
cyclic structure is 8 or less, stability of a cyclic carbodiimide
compound is reduced, and there are cases where storage and usage
become difficult. In addition, from the viewpoint of reactivity,
the upper limit value of the number of membered-ring is not
particularly limited, however, in a case of a cyclic carbodiimide
compound having the number of atoms greater than 50, a case where
cost is significantly increased due to the difficulty in synthesis
occurs. From these viewpoints, in Formula (O-1), the range of the
number of atoms in the cyclic structure is preferably 10 to 30,
more preferably 10 to 20, and particularly preferably 10 to 15.
[0091] Next, the cyclic carbodiimide compound which is represented
by Formula (O-2) will be described.
##STR00011##
[0092] In Formula (O-2), each of R.sup.11, R.sup.15, R.sup.21, and
R.sup.25 independently represents an alkyl group, an aryl group, or
an alkoxy group. Each of R.sup.12 to R.sup.14, R.sup.16 to
R.sup.18, R.sup.22 to R.sup.24, and R.sup.26 to R.sup.28
independently represents a hydrogen atom, an alkyl group, an aryl
group, or an alkoxy group. R.sup.11 to R.sup.28 may be bonded to
each other to form a ring. Each of X.sup.11, X.sup.12, X.sup.21,
and X.sup.22 independently represents a single bond, --O--, --CO--,
--S--, --SO.sub.2--, --NH--, or --CH.sub.2--. L.sup.2 represents a
tetravalent linking group.)
[0093] The preferable range of R.sup.11, R.sup.15, R.sup.21, and
R.sup.25 in Formula (O-2) is the same as the preferable range of
R.sup.1 and R.sup.5 in Formula (O-1). The aryl group which is
represented by R.sup.11, R.sup.15, R.sup.21, or R.sup.25 may be an
aryl group formed by condensation of R.sup.11 and R.sup.12,
condensation of R.sup.15 and R.sup.16, condensation of R.sup.21 and
R.sup.22, or condensation of R.sup.25 and R.sup.26, and each of
R.sup.11, R.sup.15, R.sup.21, or R.sup.25 preferably does not form
a ring by condensation with R.sup.12, R.sup.16, R.sup.22, or
R.sup.26.
[0094] R.sup.11, R.sup.15, R.sup.21, and R.sup.25 may be the same
as or different from each other, and are preferably the same from
the viewpoint of cost.
[0095] The preferable range of R.sup.12 to R.sup.14, R.sup.16 to
R.sup.18, R.sup.22 to R.sup.24, and R.sup.26 to R.sup.28 in Formula
(O-2) is the same as the preferable range of R.sup.2 to R.sup.4 and
R.sup.6 to R.sup.8 in Formula (O-1).
[0096] In R.sup.12 to R.sup.14, R.sup.16 to R.sup.18, R.sup.22 to
R.sup.24, and R.sup.26 to R.sup.28, all of R.sup.12, R.sup.16,
R.sup.22, and R.sup.26 are preferably hydrogen atoms from the
viewpoint of ease of introducing a bulky substituent to R.sup.11,
R.sup.15, R.sup.21, or R.sup.25.
[0097] In Formula (O-2), R.sup.11 to R.sup.28 may be bonded to each
other to form a ring, and the preferable range of the ring is the
same as the range of the ring formed when R.sup.1 to R.sup.8 in
Formula (O-1) are bonded to each other.
[0098] The preferable range of X.sup.11, X.sup.12, X.sup.21, and
X.sup.22 in Formula (O-2) is the same as the preferable range of
X.sup.1 and X.sup.2 in Formula (O-1).
[0099] In Formula (O-2), L.sup.2 represents a tetravalent linking
group, and is preferably a tetravalent aliphatic group having 1 to
20 carbon atoms, a tetravalent alicyclic group having 3 to 20
carbon atoms, a tetravalent aromatic group having 5 to 15 carbon
atoms which may include a heteroatom or a substituent,
respectively, or a combination of these, and more preferably a
tetravalent aliphatic group having 1 to 20 carbon atoms.
[0100] As a tetravalent aliphatic group which is represented by
L.sup.2, an alkanetetrayl group having 1 to 20 carbon atoms and the
like can be exemplified. Examples of the alkanetetrayl group having
1 to 20 carbon atoms include a methanetetrayl group, an
ethanetetrayl group, a propanetetrayl group, a butanetetrayl group,
pentanetetrayl group, a hexanetetrayl group, a heptanetetrayl
group, an octanetetrayl group, a nonanetetrayl group, a
decanetetrayl group, a dodecanetetrayl group, and a
hexadecanetetrayl group, a methanetetrayl group, an ethanetetrayl
group, and a propanetetrayl group are more preferable, and an
ethanetetrayl group is particularly preferable. These aliphatic
groups may include substituents. Examples of the substituents
include an alkyl group having 1 to 20 carbon atoms, an aryl group
having 6 to 15 carbon atoms, a halogen atom, a nitro group, an
amide group, a hydroxyl group, an ester group, an ether group, and
an aldehyde group.
[0101] As a tetravalent alicyclic group which is represented by
L.sup.2, a cycloalkanetetrayl group having 3 to 20 carbon atoms can
be exemplified. Examples of the cycloalkanetetrayl group having 3
to 20 carbon atoms include a cyclopropanetetrayl group, a
cyclobutanetetrayl group, a cyclopentanetetrayl group, a
cyclohexanetetrayl group, a cycloheptanetetrayl group, a
cyclooctanetetrayl group, a cyclononanetetrayl group, a
cyclodecanetetrayl group, a cyclododecanetetrayl group, and a
cyclohexadecanetetrayl group. These alicyclic groups may include
substituents. Examples of the substituents include an alkyl group
having 1 to 20 carbon atoms, an arylene group having 6 to 15 carbon
atoms, a halogen atom, a nitro group, an amide group, a hydroxyl
group, an ester group, an ether group, and an aldehyde group.
[0102] As a tetravalent aromatic group which is represented by
L.sup.2, an arenetetrayl group having 5 to 15 carbon atoms which
may have a heterocyclic structure by including a heteroatom can be
exemplified. As the arenetetrayl group (tetravalent) having 5 to 15
carbon atoms, a benzenetetrayl group and a naphthalenetetrayl group
can be exemplified. These aromatic groups may be substituted.
Examples of the substituents include an alkyl group having 1 to 20
carbon atoms, an aryl group having 6 to 15 carbon atoms, a halogen
atom, a nitro group, an amide group, a hydroxyl group, an ester
group, an ether group, and an aldehyde group.
[0103] In Formula (O-2), two cyclic structure including
carbodiimide groups through L2 which is a tetravalent linking group
is included.
[0104] The preferable range of the number of atoms in the cyclic
structure including each carbodiimide group in Formula (0-2) is the
same as the preferable range of the number of atoms in the cyclic
structure including a carbodiimide group in Formula (0-1),
respectively.
[0105] The cyclic carbodiimide compound of the present invention is
preferably an aromatic carbodiimide that does not have a ring
structure in which the first nitrogen and the second nitrogen of
two or more carbodiimide groups in a molecule are bonded with a
linking group, in other words, an aromatic carbodiimide that is
monocyclic, and represented by Formula (O-1) from the viewpoint of
difficulty in thickening.
[0106] However, from the viewpoint of suppressing volatilization
and generation of isocyanate gas during the production, the cyclic
carbodiimide compound of the present invention is also preferably a
cyclic carbodiimide compound which has a plurality of cyclic
structures and is represented by Formula (O-2).
[0107] The molecular weight of the cyclic carbodiimide compound of
the present invention is preferably 400 or greater since the
volatility is low and it is possible to suppress generation of
isocyanate gas during the production. In addition, the upper limit
of the molecular weight of the cyclic carbodiimide compound of the
present invention is not particularly limited as long as it does
not impair the effect of the present invention, but from the
viewpoint of reactivity with carboxylic acid, the upper limit is
preferably 1,500 or less.
[0108] The molecular weight of the cyclic carbodiimide compound of
the present invention is more preferably 500 to 1,200.
[0109] As specific examples of the cyclic carbodiimide compound
which is represented by Formula (O-1) or (O-2), that is, specific
examples of the cyclic carbodiimide compound of the present
invention, the following compounds can be exemplified. However, the
present invention is not limited to the following specific
examples.
##STR00012## ##STR00013## ##STR00014##
[0110] The cyclic carbodiimide compound of the present invention is
a compound having at least one structure (carbodiimide group) which
is represented by --N.dbd.C.dbd.N-- adjacent to an aromatic ring,
and can be produced, for example, by heating an organic isocyanate,
in the presence of an appropriate catalyst, to perform a
decarboxylation reaction. In addition, the cyclic carbodiimide
compound of the present invention can be synthesized by referencing
a method described in JP-A-2011-256337.
[0111] When synthesizing a cyclic carbodiimide compound of the
present invention, as a method for introducing a specific bulky
substituent to an ortho-position of an arylene group adjacent to a
first nitrogen and a second nitrogen in a carbodiimide group is not
particularly limited, and for example, by nitrating alkyl benzene
by a known method, it is possible to synthesize nitrobenzene in
which the alkyl group is substituted, and it is possible to
synthesize a cyclic carbodiimide using the nitrobenzene by a method
described in WO2011/158958.
[0112] Here, it is also considered that in order to increase the
hydrolysis resistance of polyester film, it is preferable to block
many carboxyl terminals of polyester. However, when putting a large
amount of cyclic carbodiimide compound such as the cyclic
carbodiimide compound of the present invention into polyester, gel
is formed and the film thickness uniformity of the polyester film
is likely to be insufficient. Therefore, by controlling the
addition amount of the cyclic carbodiimide compound of the present
invention to be a specific range, it is easy to control both
hydrolysis resistance and film thickness uniformity of the
polyester film to be a preferable range. Moreover, the cyclic
polycarbodiimide compound put in a large amount for a secondary
reaction remains as the unreacted cyclic carbodiimide compound, and
further, it may be reacted with moisture, the terminal group of
polyester, or other free acid, and thus to be decomposed into
isocyanates in some cases.
[0113] The polyester film of the present invention includes the
cyclic carbodiimide compound of the present invention in an amount
of 0.05% by mass to 5% by mass relative to 100% by mass of the
polyester. It is preferable that the polyester film include the
cyclic carbodiimide compound of the lower limit value or greater
from the viewpoint of improving both hydrolysis resistance and film
thickness uniformity. It is preferable that the polyester film
include the cyclic carbodiimide compound of the upper limit value
or less from the viewpoint of suppressing gelation and improving
film thickness uniformity of the polyester film of the present
invention.
[0114] The polyester film of the present invention more preferably
includes the cyclic carbodiimide compound of the present invention
in an amount of 0.1% by mass to 2% by mass, and particularly
preferably includes 0.1% by mass to 1% by mass, relative to 100% by
mass of the polyester.
[0115] The polyester film of the present invention does not refuse
to include a carbodiimide compound other than the cyclic
carbodiimide compound of the present invention as long as it is not
contrary to the spirit of the present invention, and 90% or greater
of a carbodiimide compound included in the polyester film of the
present invention is preferably the cyclic carbodiimide compound of
the present invention, 95% or greater is more preferably the cyclic
carbodiimide compound of the present invention, and 100% is
particularly preferably the cyclic carbodiimide compound of the
present invention.
[0116] <Configuration and Characteristics of Polyester
Film>
[0117] The thickness of the polyester film of the present invention
varies according to the uses, but in the case where the polyester
film is used as a member of a back sheet for a solar cell module,
the thickness is preferably 25 .mu.m to 300 .mu.m, and more
preferably 120 .mu.m to 300 .mu.m. When the thickness is 25 .mu.m
or greater, a sufficient dynamic strength is obtained, whereas a
thickness set to be 300 .mu.m or less is advantageous in terms of
cost.
[0118] The polyester film of the present invention is preferably
stretched, more preferably biaxially stretched, and particularly
preferably biaxially stretched in plane compared to stretching of a
tubular shape, and more particularly preferably sequentially
biaxially stretched.
[0119] The degree of MD orientation and the degree of TD
orientation of the polyester film of the present invention are each
preferably 0.14 or greater, more preferably 0.155 or greater, and
particularly preferably 0.16 or greater. If each degree of
orientation is 0.14 or greater, the restriction of the
non-crystalline chain is improved (the mobility is lowered), and
the hydrolysis resistance is improved. The degree of MD orientation
and the degree of TD orientation can be calculated from the degree
of MD orientation: .DELTA.n(x-z), TD; .DELTA.n(y-z), by measuring
the refractive indices in the x, y, and z directions of the
biaxially oriented film at an atmosphere at 25.degree. C., using an
Abbe refractometer, a monochromatic light sodium D-line as the
light source, and methylene iodide as a mounting solution.
[0120] In addition, the intrinsic viscosity (IV) of the polyester
film of the present invention is preferably 0.70 dl/g to 0.94 dl/g,
more preferably 0.71 dl/g to 0.84 dl/g, and particularly preferably
0.72 dl/g to 0.84 dl/g.
[0121] The intrinsic viscosity of the polyester film is preferably
the lower limit value described above or less from the viewpoint of
improving film formation properties and the film thickness
uniformity.
[0122] <Production Method of Polyester Film>
[0123] (Film Forming Step)
[0124] In the film forming step, the melt obtained by meting the
polyester and the cyclic carbodiimide compound included in the
resin composition for forming the polyester film of the present
invention is passed through a gear pump or a filter, then extruded
from a cooling roll through a die, and cooled and solidified,
whereby a (unstretched) film can be formed. In this regard, the
extruded melt can be adhered to the cooling roll using an
electrostatic application method. At this time, the surface
temperature of the cooling roll can be usually set to 10.degree. C.
to 40.degree. C.
[0125] (Stretching Step)
[0126] The (unstretched) film formed by the film forming step can
be realized by carrying out a stretching treatment in the
stretching step. In the stretching step, a cooling-solidified
(unstretched) film is preferably stretched in one or two
directions, and more preferably stretched in two directions. The
stretching in two directions (biaxial stretching) is preferably
stretching in the length direction (MD: Machine Direction) (which
is hereinafter also referred to as "longitudinal stretching") and
in the width direction (TD: Transverse Direction) (which may be
hereinafter also referred to as a "transverse stretching". The
longitudinal stretching and the transverse stretching can be
performed once, respectively, or may be performed in plural times,
and the longitudinal stretching and the transverse stretching may
be performed at the same time.
[0127] The stretching treatment is performed, preferably at the
glass temperature (Tg).degree. C. of the film to (Tg+60).degree.
C., and more preferably Tg+3.degree. C. to Tg+40.degree. C., and
more preferably at Tg+5.degree. C. to Tg+30.degree. C.
[0128] The preferable stretching ratio is 280% to 500%, more
preferably 300% to 480%, and even more preferably 320% to 460% in
at least one direction. In the case of biaxial stretching, the
stretching may be performed equivalently in the longitudinal and
the transverse directions, but it is more preferable that the
stretching ratio in one direction is larger than that in the other
direction, thereby carrying out inequivalent stretching. Any one of
the longitudinal direction (MD) and the transverse direction (TD)
may be larger than the other. The stretching ratio as mentioned
herein is determined using the following formula.
Stretching ratio (%)=100{(Length after stretching)-(Length before
stretching)}/(Length before stretching)
[0129] The biaxial stretching treatment is a stretching, for
example, at the glass transition temperature (Tg.sub.1).degree. C.
of a film to (Tg.sub.1+60).degree. C. in the length direction once
or two or more times, in which the total ratio is 3- to 6-times and
the ratio in the width ration at (Tg.sub.1).degree. C. to
(Tg+60).degree. C. is 3- to 5-times.
[0130] The biaxial stretching treatment can be performed by
stretching in the length direction, using two or more nip rolls
that have a higher peripheral speed at an outlet (longitudinal
stretching), and can also performed by gripping both ends of the
film with chucks and extending them in the perpendicular direction
(the direction perpendicular to the length direction) (transverse
stretching).
[0131] In the stretching step, before the stretching treatment or
after the stretching treatment, and preferably after stretching
treatment, the film can be subjected to a heat treatment. By
carrying out the heat treatment, fine crystals can be produced,
thereby improving the dynamic characteristics or durability. The
film can also be subjected to a heat treatment at about 180.degree.
C. to 210.degree. C. (more preferably at 185.degree. C. to
210.degree. C.) for 1 second to 60 seconds (more preferably for 2
seconds to 30 seconds).
[0132] In the stretching step, the thermal relaxation treatment can
be performed after the heat treatment. The thermal relaxation
treatment is a treatment for shrinking the film by applying heat to
the film for stress relaxation. The thermal relaxation treatment is
preferably performed in both directions of the MD direction and the
TD direction of the film. For the conditions in the thermal
relaxation treatment, the treatment is preferably performed at a
temperature lower than the heat treatment temperature, and more
preferably at 130.degree. C. to 205.degree. C. Further, for the
thermal relaxation treatment, the thermal shrinkage (150.degree.
C.) of the film in both of the MD and the TD is preferably 1% to
12%, and more preferably 1% to 10%. However, the thermal shrinkage
(150.degree. C.) is determined as follows. The thermal shrinkage
can be determined from the following formula, by cutting out a
sample having a width of 50 mm at 350 mm in the measurement
direction, attaching a target point at an interval of 300 mm near
the both ends in the length direction of the sample, fixing one end
in an oven adjusted to a temperature of 150.degree. C., leaving the
other end to be free for 30 minutes, then measuring the distance
between the target points at room temperature, taking this length
as L (mm), and using this measured values.
150.degree. C. thermal shrinkage (%)=100.times.(300-L)/300
[0133] In addition, a case where the thermal shrinkage is positive
denotes shrinkage, and a case where the thermal shrinkage is
negative denotes stretching.
[0134] As described above, according to the method described above,
a film having excellent hydrolysis resistance can be fabricated.
The polyester film of the present invention can be appropriately
used not only as a protective sheet (back sheet for a solar cell
module) for a solar cell module as described below, but also in
other applications.
[0135] In addition, the film of the present invention can also be
used as a laminate including a coating layer containing at least
one functional group selected from COON, OH, SO.sub.3H, NH.sub.2,
and a salt thereof thereon.
[0136] [Back Sheet for Solar Cell Module]
[0137] The back sheet for a solar cell module of the present
invention may include the polyester film of the present invention.
If the polyester film of the present invention is used for a back
sheet for a solar cell module, a problem in adhesiveness among the
layers is reduced, and thus, particularly, adhesiveness among the
layers after wet heat aging can be greatly improved.
[0138] The back sheet for a solar cell module of the present
invention may have the following functional layer applied to the
polyester film by coating after uniaxial stretching and/or after
biaxial stretching. For the application, known coating techniques
such as a roll coating method, a knife edge coating method, a
gravure coating method, a curtain coating method, and the like can
be used.
[0139] In addition, a surface treatment (a flame treatment, a
corona treatment, a plasma treatment, an ultraviolet treatment, and
the like) may also be performed before such the application.
Further, bonding using an adhesive is also preferable.
[0140] --Readily Adhesive Layer--
[0141] In the polyester film of the present invention, a readily
adhesive layer is preferably provided on the side facing the
sealing material of the battery-side substrate, in which a
photovoltaic cell is sealed with a sealing material in the case of
constituting the solar cell module. By providing a readily adhesive
layer exhibiting adhesiveness to an adherend (for example, the
surface of the battery-side substrate and the sealing material, in
which the photovoltaic cell is sealed with a sealing material)
including a sealing material (in particular, an ethylene-vinyl
acetate copolymer), it is possible to adhere firmly between the
back sheet and the sealing material. Specifically, the readily
adhesive layer preferably has an adhesion power, in particular with
EVA (an ethylene-vinyl acetate copolymer) used as a sealing
material, of 10 N/cm or greater, and preferably 20 N/cm or
greater.
[0142] Further, for the readily adhesive layer, it is required that
peeling of the back sheet should not occur during the use of the
solar cell module, and thus, it is preferable the readily adhesive
layer have high hydrolysis resistance.
[0143] (1) Binder
[0144] The readily adhesive layer according to the present
invention can contain at least one binder.
[0145] As the binder, a polyester, a polyurethane, an acrylic
resin, a polyolefin, or the like can be used. Among these, from the
viewpoint of durability, an acrylic resin and polyolefin are
preferable. Further, as the acrylic resin, a composite resin of an
acryl and a silicone is also preferable. Preferable examples of the
binder include the following compounds.
[0146] Examples of the polyolefin include CHEMIPEARL S-120 and
CHEMIPEARL S-75N (both manufactured by Mitsui Chemicals, Inc.).
Examples of the acrylic resin include JURYMER ET-410 and JURYMER
SEK-301 (both manufactured by Nihon Junyaku Co., Ltd.).
Furthermore, examples of the composite resin of an acryl and a
silicone include CERANATE WSA1060 and CERANATE WSA1070 (both
manufactured by DIC Corp.), and H7620, H7630, and H7650 (all
manufactured by Asahi Kasei Chemicals Corp.). The amount of the
binder is preferably in the range of 0.05 g/m.sup.2 to 5 g/m.sup.2,
and particularly preferably in the range of 0.08 g/m.sup.2 to 3
g/m.sup.2.
[0147] When the amount of the binder is 0.05 g/m.sup.2 or greater,
a more satisfactory adhesive power is obtained, and when the amount
of the binder is 5 g/m.sup.2 or less, a better surface shape is
obtained.
[0148] (2) Fine Particles
[0149] The readily adhesive layer in the present invention can
contain at least one kind of fine particles. The readily adhesive
layer preferably contains the fine particles in an amount of 5% by
mass or greater with respect to the total mass of the layer.
[0150] Suitable examples of the fine particles include inorganic
fine particles of silica, calcium carbonate, magnesium oxide,
magnesium carbonate, tin oxide, and the like.
[0151] Particularly among these, from the viewpoint that a decrease
in the adhesiveness is small when exposed to a high-temperature and
high-humidity atmosphere, fine particles of tin oxide and silica
are preferable.
[0152] The particle diameter of the fine particles is preferably
about 10 nm to 700 nm, and more preferably about 20 nm to 300 nm.
When fine particles having a particle diameter in the range
described above are used, satisfactory high adhesiveness can be
obtained. There are no particular limitations on the shape of the
fine particles, but fine particles having a spherical shape, an
indefinite shape, a needle-like shape, and the like can be
used.
[0153] The amount of the fine particles to be added in the readily
adhesive layer is preferably 5% by mass to 400% by mass, and more
preferably 50% by mass to 300% by mass, relative to 100% by mass of
the binder in the readily adhesive layer.
[0154] When the amount of the fine particles to be added is 5% by
mass or greater, the adhesiveness when the readily adhesive layer
is exposed to a high-temperature and high-humidity atmosphere is
excellent. When the amount to be added is 1000% by mass or less,
the surface shape of the readily adhesive layer is better.
[0155] (3) Crosslinking Agent
[0156] The readily adhesive layer in the present invention can
contain at least one crosslinking agent.
[0157] Examples of the crosslinking agent include an epoxy-based
crosslinking agent, an isocyanate-based crosslinking agent, a
melamine-based crosslinking agent, a carbodiimide-based
crosslinking agent, an oxazoline-based crosslinking agent, and the
like. From the viewpoint of securing the adhesiveness after wet
heat aging, among these, an oxazoline-based crosslinking agent is
particularly preferable.
[0158] Specific examples of the oxazoline-based crosslinking agent
include 2-vinyl-2-oxazoline, 2-vinyl-4-methyl-2-oxazoline,
2-vinyl-5-methyl-2-oxazoline, 2-isopropenyl-2-oxazoline,
2-isopropenyl-4-methyl-2-oxazoline,
2-isopropenyl-5-ethyl-2-oxazoline, 2,2'-bis-(2-oxazoline),
2,2'-methylene-bis-(2-oxazoline), 2,2'-ethylene-bis-(2-oxazoline),
2,2'-trimethylene-bis-(2-oxazoline),
2,2'-tetramethylene-bis-(2-oxazoline),
2,2'-hexamethylene-bis-(2-oxazoline),
2,2'-octamethylene-bis-(2-oxazoline),
2,2'-ethylene-bis-(4,4'-dimethyl-2-oxazoline),
2,2'-p-phenylene-bis-(2-oxazoline),
2,2'-m-phenylene-bis-(2-oxazoline),
2,2'-m-phenylene-bis-(4,4'-dimethyl-2-oxazoline),
bis-(2-oxazolinylcyclohexane)sulfide,
bis-(2-oxazolinylnorbornane)sulfide, and the like.
[0159] In addition, (co)polymers of these compounds can also be
preferably used.
[0160] Furthermore, as a compound having an oxazoline group,
EPOCROS K2010E, EPOCROS K2020E, EPOCROS K2030E, EPOCROS WS500, and
EPOCROS WS700 (all manufactured by Nippon Shokubai Co., Ltd.), and
the like can also be used.
[0161] A preferable amount of the crosslinking agent to be added in
the readily adhesive layer is preferably 5% by mass to 50% by mass,
and more preferably 20% by mass to 40% by mass, relative to 100% by
mass of the binder in the readily adhesive layer. When the amount
of the crosslinking agent to be added is 5% by mass or greater, a
good crosslinking effect is obtained, and a decrease in the
strength of the reflective layer or adhesion failure does not
easily occur. When the amount of the crosslinking agent to be added
is 50% by mass or less, the pot life of the coating liquid can be
maintained longer.
[0162] (4) Additives
[0163] To the readily adhesive layer in the present invention, a
known mat agent such as polystyrene, polymethyl methacrylate,
silica, and the like; a known surfactant such as an anionic
surfactant, a nonionic surfactant, and the like; etc. may also be
further added, if desired.
[0164] (5) Method for Forming Readily Adhesive Layer
[0165] Examples of the method for forming the readily adhesive
layer in the present invention include a method of bonding a
polymer sheet having high adhesiveness to the polyester film, and a
method based on coating. A method based on coating is preferable
from the viewpoint of being convenient and capable of forming a
highly uniform thin film. As the coating method, for example, a
known method of using a gravure coater or a bar coater can be used.
The solvent for the coating liquid that is used for coating may be
water, or an organic solvent such as toluene and methyl ethyl
ketone. The solvents may be used singly or as a mixture of two or
more kinds thereof.
[0166] In addition, in the case of forming a readily adhesive layer
by coating, both of drying of the coating layer in a drying zone
after the heat treatment as described above, and a heat treatment
is preferably included. Further, a case of forming the colored
layer as described later or the other functional layers by coating
is also preferable.
[0167] (6) Physical Properties of Readily Adhesive Layer
[0168] The thickness of the readily adhesive layer in the present
invention is not particularly limited, but usually, the thickness
is preferably 0.05 .mu.m to 8 .mu.m, and more preferably in the
range of 0.1 .mu.m to 5 .mu.m. When the thickness of the readily
adhesive layer is 0.05 .mu.m or greater, the high adhesiveness that
is needed can be easily obtained, and when the thickness is 8 .mu.m
or less, the surface shape can be maintained more
satisfactorily.
[0169] Furthermore, the readily adhesive layer in the present
invention is preferably transparent from the viewpoint that when a
colored layer (particularly a reflective layer) is arranged between
the readily adhesive layer and the polyester film, the readily
adhesive layer does not impair the effect of the colored layer.
[0170] --Colored Layer--
[0171] The polyester film of the present invention can be provided
with a colored layer. The colored layer is a layer arranged to be
in contact with the surface of the polyester film or with another
layer interposed therebetween, and can be constructed using a
pigment or a binder.
[0172] A first function of the colored layer is to increase the
power generation efficiency of a solar cell module by reflecting a
portion of light in the incident light, which is not used in the
power generation at the photovoltaic cell and reaches the back
sheet, and returning the portion of light to the photovoltaic cell.
A second function is to enhance the decorative properties of the
external appearance when the solar cell module is viewed from the
front surface side. Generally, when a solar cell module is viewed
from the front surface side, the back sheet is seen around the
photovoltaic cell. Thus, the decorative properties can be increased
by providing a colored layer to the back sheet.
[0173] (1) Pigment
[0174] The colored layer in the present invention can contain at
least one pigment. The pigment is preferably included in an amount
in the range of 2.5 g/m.sup.2 to 8.5 g/m.sup.2. A more preferable
pigment content is in the range of 4.5 g/m.sup.2 to 7.5 g/m.sup.2.
When the pigment content is 2.5 g/m.sup.2 or greater, necessary
coloration can be easily obtained, and the light reflectivity or
decorative properties can be further improved. When the pigment
content is 8.5 g/m.sup.2 or less, the surface shape of the colored
layer can be maintained more satisfactorily.
[0175] Examples of the pigment include inorganic pigments such as
titanium oxide, barium sulfate, silicon oxide, aluminum oxide,
magnesium oxide, calcium carbonate, kaolin, talc, ultramarine blue,
Prussian blue, carbon black, and the like; and organic pigments
such as phthalocyanine blue, phthalocyanine green, and the like.
Among these pigments, a white pigment is preferable from the
viewpoint of constituting the colored layer as a reflective layer
that reflects sunlight incident thereon. Preferable examples of the
white pigment include titanium oxide, barium sulfate, silicon
oxide, aluminum oxide, magnesium oxide, calcium carbonate, kaolin,
talc, and the like.
[0176] The average particle diameter of the pigment is preferably
0.03 .mu.m to 0.8 .mu.m, and more preferably about 0.15 .mu.m to
0.5 .mu.m. When the average particle diameter is in the range
described above, the light reflection efficiency may be
lowered.
[0177] In the case of constructing the colored layer as a
reflective layer that reflects sunlight that has entered, the
preferable amount of the pigment to be added in the reflective
layer varies with the type or average particle diameter of the
pigment used and cannot be defined briefly. However, the amount of
the pigment to be added is preferably 1.5 g/m.sup.2 to 15
g/m.sup.2, and more preferably about 3 g/m.sup.2 to 10 g/m.sup.2.
When the addition amount thereof is 1.5 g/m.sup.2 or greater, a
necessary reflectance can be easily obtained, and when the addition
amount thereof is 15 g/m.sup.2 or less, the strength of the
reflective layer can be maintained at a higher level.
[0178] (2) Binder
[0179] The colored layer in the present invention can contain at
least one binder. When the colored layer contains a binder, the
amount of the binder is preferably in the range of 15% by mass to
200% by mass, and more preferably in the range of 17% by mass to
100% by mass, relative to 100% by mass of the pigment. When the
amount of the binder is 15% by mass or greater, the strength of the
colored layer can be maintained more satisfactorily, and when the
amount is 200% by mass or less, the reflectance or decorative
properties is lowered.
[0180] As the binder suitable for the colored layer, a polyester, a
polyurethane, an acrylic resin, a polyolefin, or the like can be
used. The binder is preferably an acrylic resin or a polyolefin
from the viewpoint of durability. As an acrylic resin, a composite
resin of an acryl and a silicone is also preferable. Preferable
examples of the binder include the following compounds.
[0181] Examples of the polyolefin include CHEMIPEARL S-120 and
CHEMIPEARL S-75N (both manufactured by Mitsui Chemicals, Inc.), and
the like. Examples of the acrylic resin include JURYMER ET-410 and
JURYMER SEK-301 (both manufactured by Nihon Junyaku Co., Ltd.), and
the like. Furthermore, examples of the composite resin of an acryl
and a silicone include CERANATE WSA1060 and CERANATE WSA1070 (both
manufactured by DIC Corp.), H7620, H7630, and H7650 (all
manufactured by Asahi Kasei Chemicals Corp.), and the like.
[0182] (3) Additives
[0183] To the colored layer in the present invention, a
crosslinking agent, a surfactant, a filler, or the like may also be
further added, if desired, in addition to the binder and the
pigment.
[0184] Examples of the crosslinking agent include an epoxy-based
crosslinking agent, an isocyanate-based crosslinking agent, a
melamine-based crosslinking agent, a carbodiimide-based
crosslinking agent, an oxazoline-based crosslinking agent, and the
like. The amount of the crosslinking agent to be added in the
colored layer is preferably 5% by mass to 50% by mass, and more
preferably 10% by mass to 40% by mass, relative to 100% by mass of
the binder in the colored layer. When the amount of the
crosslinking agent to be added is 5% by mass or greater, a good
crosslinking effect is obtained, and the strength or adhesiveness
of the colored layer can be maintained at a high level. When the
amount of the crosslinking agent to be added is 50% by mass or
less, the pot life of the coating liquid can be maintained
longer.
[0185] As the surfactant, a known surfactant such as an anionic
surfactant, a nonionic surfactant, and the like can be used. The
amount of the surfactant to be added is preferably 0.1 mg/m.sup.2
to 15 mg/m.sup.2, and more preferably 0.5 mg/m.sup.2 to 5
mg/m.sup.2. When the amount of the surfactant to be added is 0.1
mg/m.sup.2 or greater, generation of cissing can be effectively
suppressed, and when the addition amount thereof is 15 mg/m.sup.2
or less, excellent adhesiveness is obtained.
[0186] Furthermore, the colored layer may also contain a filler
such as silica and the like, in addition to the pigments described
above. The amount of the filler to be added is preferably 20% by
mass or less, and more preferably 15% by mass or less, relative to
100% by mass of the binder in the colored layer. When the colored
layer contains a filler, the strength of the colored layer can be
increased. Furthermore, when the amount of the filler to be added
is 20% by mass or less, the proportion of the pigment can be
retained, and therefore, satisfactory light reflectivity
(reflectance) or decorative properties are obtained.
[0187] (4) Method for Forming Colored Layer
[0188] Examples of the method for forming the colored layer include
a method of bonding a polymer sheet containing a pigment on the
polyester film, a method of co-extruding the colored layer during
the molding of the polyester film, and a method based on coating.
Among these, the method by coating is preferable from the viewpoint
of being convenient and capable of forming a highly uniform thin
film. As the coating method, for example, a known method of using a
gravure coater or a bar coater can be used. The solvent for the
coating liquid used in the coating may be water, or may be an
organic solvent such as toluene, methyl ethyl ketone, and the like.
However, from the viewpoint of environmental burden, it is
preferable to use water as the solvent.
[0189] The solvents may be used singly or as a mixture of two or
more kinds thereof.
[0190] (5) Physical Properties of Colored Layer
[0191] It is preferable that the colored layer contain a white
pigment and is constructed as a white layer (light reflective
layer). In the case where the colored layer is a reflective layer,
the light reflectance for light at 550 nm is preferably 75% or
greater. When the reflectance is 75% or greater, the portion of
sunlight that passes through the photovoltaic cell and is not used
in power generation can be returned to the cell, and a large effect
of increasing the power generation efficiency is obtained.
[0192] The thickness of the white layer (light reflective layer) is
preferably 1 .mu.m to 20 .mu.m, more preferably 1 .mu.m to 10
.mu.m, and even more preferably about 1.5 .mu.m to 10 .mu.m. When
the thickness is 1 .mu.m or greater, necessary decorative
properties or a reflectance can be easily obtained, and when the
thickness is 20 .mu.m or less, the surface shape may be
deteriorated in some cases.
[0193] --Undercoat Layer--
[0194] The polyester film in the present invention can be provided
with an undercoat layer. For example, when a colored layer is
provided, the undercoat layer may be provided between the colored
layer and the polyester film. The undercoat layer can be
constructed by using a binder, a crosslinking agent, a surfactant,
or the like.
[0195] Examples of the binder contained in the undercoat layer
include polyester, polyurethane, an acrylic resin, a polyolefin,
and the like. To the undercoat layer, crosslinking agents such as
an epoxy-based crosslinking agent, an isocyanate-based crosslinking
agent, a melamine-based crosslinking agent, a carbodiimide-based
crosslinking agent, an oxazoline-based crosslinking agent, and the
like; surfactants such as an anionic surfactant, a nonionic
surfactant, and the like; a filler such as silica and the like;
etc. may be added, in addition to the binder.
[0196] There are no particular limitations on the method for
coating and forming the undercoat layer, or the solvent for the
coating liquid used in the method.
[0197] As the coating method, for example, a gravure coater or a
bar coater can be used. The solvent may be water, or may be an
organic solvent such as toluene, methyl ethyl ketone, and the like.
The solvents may be used singly or as a mixture of two or more
kinds thereof.
[0198] Coating may be performed such that the undercoat layer may
be applied on a polyester film obtained after biaxial stretching,
or may be applied on a polyester film obtained after uniaxial
stretching. In this case, the polyester film may be further
stretched, after applying the undercoat layer, in the direction
different from the direction of initial stretching. Furthermore,
the undercoat layer may be applied on a polyester film prior to
stretching, and then the polyester film may be stretched in two
directions.
[0199] The thickness of the undercoat layer is preferably 0.05
.mu.m to 2 .mu.m, and more preferably in the range of about 0.1
.mu.m to 1.5 .mu.m. When the film thickness of the layer is 0.05
.mu.m or greater, necessary adhesiveness can be easily obtained,
and when the thickness is 2 .mu.m or less, the surface shape can be
maintained satisfactorily.
[0200] --Antifouling Layer (Fluorine-Based Resin Layer and
Silicon-Based Resin Layer)--
[0201] The polyester film of the present invention is preferably
provided with at least one of a fluorine-based resin layer and a
silicon-based (Si-based) resin layer as an antifouling layer. When
a fluorine-based resin layer or a Si-based resin layer is provided,
prevention of contamination of the polyester surface and an
enhancement of weather resistance can be promoted. Specifically, it
is preferable that the polyester film have a fluorine resin-based
coating layer such as those described in JP-A-2007-35694 and
JP-A-2008-28294, and WO 2007/063698.
[0202] Furthermore, it is also preferable that a fluorine-based
resin film such as TEDLAR (manufactured by DuPont Company) be
adhered to the polyester film.
[0203] The thicknesses of the fluorine-based resin layer and the
Si-based resin layer are respectively preferably in the range of 1
.mu.m to 50 .mu.m, more preferably in the range of 1 .mu.m to 40
.mu.m, and even more preferably 1 .mu.m to 10 .mu.m.
[0204] [Solar Cell Module]
[0205] The solar cell module of the present invention may include
the polyester film or the back sheet for a solar cell module of the
present invention.
[0206] The solar cell module of the present invention is
constituted such that a photovoltaic cell that converts the light
energy of sunlight to electrical energy be arranged between a
transparent substrate, on which sunlight is incident, and the
polyester film (back sheet for a solar cell) of the present
invention. The space between the substrate and the polyester film
can be configured to be sealed with a resin (a so-called sealing
material) such as an ethylene-vinyl acetate copolymer and the
like.
[0207] The details of the solar cell module, the photovoltaic cell,
and the members other than the back sheet are described in, for
example, "Constituent Materials for Photovoltaic Power Generation
System" (edited by Eiichi Sugimoto, Kogyo Chosakai Publishing Co.,
Ltd. published in 2008).
[0208] The transparent substrate may desirably have light
transmitting properties by which sunlight can be transmitted, and
can be appropriately selected from base materials that transmit
light. From the viewpoint of power generation efficiency, a base
material having higher light transmittance is preferable, and as
such a substrate, for example, a glass substrate, a substrate of a
transparent resin such as an acrylic resin and the like, etc. can
be suitably used.
[0209] As the photovoltaic cell, various known photovoltaic cells
such as silicon-based elements such as single crystal silicon,
polycrystalline silicon, amorphous silicon, and the like; Group
III-V or Group II-VI compound semiconductor-based elements such as
copper-indium-gallium-selenium, copper-indium-selenium,
cadmium-tellurium, gallium-arsenic, and the like; etc. may be
applied.
EXAMPLES
[0210] Hereinafter, the present invention will be described in more
detail with reference to the following Examples. In Examples as
described below, the material, the amounts and ratios thereof, the
details of the treatment, the treatment procedure, and the like may
be suitably modified within a range not departing from the spirit
of the present invention. Therefore, the range of the present
invention should not be construed to be limited by the Examples as
described below. Unless otherwise specifically indicated, the
"part(s)" is on the basis of mass.
[0211] As a carbodiimide-based terminal blocking agent, the
following compounds were used in each Comparative Example.
Moreover, cyclic carbodiimide (1) used in Comparative Example was a
compound having the molecular weight of 252 described in Example of
JP-A-2011-258641, and was synthesized with reference to the
synthesis method described in Reference Example 1 of
JP-A-2011-258641.
[0212] Cyclic carbodiimide (2) used in Comparative Example was a
compound having the molecular weight of 516 described in Example of
JP-A-2011-258641, and was synthesized with reference to the
synthesis method described in Reference Example 2 of
JP-A-2011-258641.
[0213] Cyclic carbodiimides (3) to (5) used in Comparative Example
was a compound described in WO2010/071211, and was synthesized with
reference to the synthesis method described in JWO2010/071211.
##STR00015##
[0214] The cyclic carbodiimide compounds which are represented by
Formula (O-1) or (O-2) of the present invention having the
following structures were used in each Example as the terminal
blocking agent.
##STR00016## ##STR00017##
[0215] Among the carbodiimide-based terminal blocking agents
described above, a compound used in each Example was synthesized by
the following method.
Synthesis Example 1
[0216] (Synthesis of Compound 1)
[0217] Carvacrol (1.0 mol) and acetic acid (1.6 L) were put into
the reactor equipped with a stirrer, a mixed solution of nitric
acid (1.1 mol) and 800 ml of acetic acid was slowly added dropwise
while stirring, extraction was performed two times on the resultant
product with ethyl acetate of 1 L, and the extracted product was
sufficiently washed with water. The obtained organic layer was
dehydrated using magnesium sulfate and concentrated. Thereafter,
the concentrated product was purified by column chromatography,
whereby 50 g of ortho-nitro material of carvacrol was obtained.
[0218] Then, the obtained nitro material (0.1 mol),
1,2-dibromoethane (0.05 mol), potassium carbonate (0.3 mol), and
200 ml of N,N-dimethylformamide were put into a reactor provided
with a stirrer and heater in N.sub.2 atmosphere, the mixture was
reacted at 130.degree. C. for 12 hours, and DMF was removed by
reducing pressure. The obtained solid material was dissolved in 200
ml of dichloromethane and liquid-liquid separation was performed
with 100 ml of water three times. The organic layer was dehydrated
with 5 g of magnesium sulfate, and dichloromethane was removed by
reducing pressure, whereby an intermediate product A (nitro
material) was obtained.
[0219] Then, the intermediate product A (0.1 mol), 5% palladium on
carbon (Pd/C) (1 g), and 200 ml of ethanol/dichloromethane (70/30)
were put into a reactor provided with a stirrer, hydrogen
substitution was performed five times, the reaction was performed
in a state in which hydrogen was supplied at 25.degree. C. all
times, and the reaction was ended when the hydrogen reduction no
longer occurs. The Pd/C was retrieved, and the mixed solvent was
removed, whereby an intermediate product B (amine material) was
obtained.
[0220] Then, the intermediate product B (0.025 mol), imidazole (0.2
mol), carbon disulfide (0.2 mol), and 150 ml of acetonitrile were
put into a reactor provided with a stirrer and a heater in N.sub.2
atmosphere. The temperature of the reaction solution was set to
80.degree. C., and the reaction was performed for 15 hours. After
the obtained acetonitrile solution was concentrated, the
concentrated product was purified by column chromatography, whereby
an intermediate product C (thiourea material) was obtained.
[0221] Then, the intermediate product C (0.025 mol), 30% NaOH
(0.052 mol), benzyltriethylammonium chloride (0.0019 mol), 170 ml
of chloroform, and 5.8 ml of methanol were put into a reactor
provided with a stirrer and the mixture was stirred. After 10.5%
aqueous solution of hypochlorite (0.103 mol) was slowly added
dropwise thereto and stirred for 1 hour, a liquid-liquid separation
was performed three times with pure water.
[0222] The obtained chloroform solution was dehydrated with
magnesium sulfate and concentrated, and the concentrated product
was washed with hexane two times, whereby an intended compound was
obtained. The structure was confirmed by NMR and IR.
[0223] .sup.1H-NMR(CDCl.sub.3) .delta. (ppm); 1.22(12H), 2.33(6H),
3.41(2H), 4.18(4H), 6.94(4H)
[0224] By the above reaction, a compound 1 was synthesized.
[Synthesis Example 2]
[0225] (Synthesis of Compound 2)
[0226] The nitro material (0.1 mol) obtained in Synthesis Example
1, pentaerythritol tetrabromide (0.025 mol), potassium carbonate
(0.3 mol), and 200 ml of N,N-dimethylformamide were put into a
reactor provided with a stirrer and heater in N.sub.2 atmosphere,
the mixture was reacted at 130.degree. C. for 30 hours, and DMF was
removed by reducing pressure. The obtained solid material was
washed with water, ethanol, and hexane, whereby an intermediate
product A (nitro material) was obtained.
[0227] Then, the intermediate product A (0.02 mol), 560 ml of
2-isopropanol, and 110 ml of 35% aqueous solution of hydrochloric
acid were put into a reactor provided with a stirrer, then, zinc
powder (0.8 mol) was slowly added thereto, and reflux was performed
for one hour. After the zinc powder was retrieved by filtration,
1.0 L of chloroform was added thereto, and a liquid-liquid
separation was performed two times with pure water. The organic
layer was dehydrated with magnesium sulfate, and chloroform was
removed by reducing pressure, whereby an intermediate product B
(amine material) was obtained.
[0228] Then, the intermediate product B (0.015 mol), imidazole
(0.03 mol), carbon disulfide (0.09 mol), and 50 ml of acetonitrile
were put into a reactor provided with a stirrer and a heater in
N.sub.2 atmosphere. The temperature of the reaction solution was
set to 100.degree. C., and the reaction was performed for 15 hours.
The solid precipitated after the reaction was retrieved by
filtration, and the resultant product was washed with acetonitrile,
whereby an intermediate product C (thiourea material) was
obtained.
[0229] Then, the intermediate product C (0.01 mol), 30% NaOH (0.04
mol), benzyltriethylammonium chloride (0.002 mol), 200 ml of
chloroform, and 6.6 ml of methanol were put into a reactor provided
with a stirrer and a heater and the mixture was stirred. After
10.5% aqueous solution of hypochlorite (0.08 mol) was slowly added
dropwise thereto and stirred for 1 hour, a liquid-liquid separation
was performed three times with pure water.
[0230] The obtained chloroform solution was dehydrated with
magnesium sulfate and concentrated, and the concentrated product
was washed with hexane two times, whereby an intended compound was
obtained. The structure was confirmed by NMR and IR.
[0231] .sup.1H-NMR(CDCl.sub.3) .delta. (ppm); 1.22(24H), 2.20(12H),
3.42(4H), 4.42(8H), 6.94(8H)
[0232] By the above reaction, a compound 2 was synthesized.
Synthesis Example 3
[0233] (Synthesis of Compound 3)
[0234] 171 g of 3-hydroxybiphenyl (1.0 mol) was dissolved in 1700
ml of nitromethane, and after cooling to 2.degree. C. in an ice
bath, 34 ml of fuming nitric acid was added dropwise thereto while
stirring, and the resultant product was stirred for 12 hours as it
is. After adding 200 ml of water thereto, extraction was performed
on the reaction product with 500 ml of chloroform, then, the
resultant product was washed with 200 ml of hydrochloric acid water
and 100 ml of water, and concentrated. Thereafter, the concentrated
product was produced by column chromatography, whereby 41 g of
2-nitro-3-hydroxybiphenyl (0.3 mol) was obtained.
[0235] Then, the obtained nitro material (0.1 mol),
1,2-dibromoethane (0.05 mol), potassium carbonate (0.3 mol), and
200 ml of N,N-dimethylformamide were put into a reactor provided
with a stirrer and heater in N.sup.2 atmosphere, the mixture was
reacted at 130.degree. C. for 12 hours, and DMF was removed by
reducing pressure. The obtained solid material was dissolved in 200
ml of dichloromethane and liquid-liquid separation was performed
with 100 ml of water three times. The organic layer was dehydrated
with 5 g of magnesium sulfate, and dichloromethane was removed by
reducing pressure, whereby an intermediate product A (nitro
material) was obtained.
[0236] Then, the intermediate product A (0.1 mol), 5% palladium on
carbon (Pd/C) (1 g), and 200 ml of ethanol/dichloromethane (70/30)
were put into a reactor provided with a stirrer, hydrogen
substitution was performed five times, the reaction was performed
in a state in which hydrogen was supplied at 25.degree. C. all
times, and the reaction was ended when the hydrogen reduction no
longer occurs. The Pd/C was retrieved, and the mixed solvent was
removed, whereby an intermediate product B (amine material) was
obtained.
[0237] Then, the intermediate product B (0.025 mol), imidazole (0.2
mol), carbon disulfide (0.2 mol), and 150 ml of acetonitrile were
put into a reactor provided with a stirrer and a heater in N.sub.2
atmosphere. The temperature of the reaction solution was set to
80.degree. C., and the reaction was performed for 15 hours. After
the obtained acetonitrile solution was concentrated, the
concentrated product was purified by column chromatography, whereby
an intermediate product C (thiourea material) was obtained.
[0238] Then, the intermediate product C (0.01 mol), 30% NaOH (0.04
mol), benzyltriethylammonium chloride (0.002 mol), 200 ml of
chloroform, and 6.6 ml of methanol were put into a reactor provided
with a stirrer and the mixture was stirred. After 10.5% aqueous
solution of hypochlorite (0.08 mol) was slowly added dropwise
thereto and stirred for 1 hour, a liquid-liquid separation was
performed three times with pure water.
[0239] The obtained chloroform solution was dehydrated with
magnesium sulfate and concentrated, and the concentrated product
was washed with hexane two times, whereby an intended compound was
obtained. The structure was confirmed by NMR and IR. By the above
reaction, a compound 3 was synthesized.
Synthesis Example 4
[0240] (Synthesis of Compound 4)
[0241] The nitro material (0.1 mol) obtained in Synthesis Example
3, pentaerythritol tetrabromide (0.025 mol), potassium carbonate
(0.3 mol), and 200 ml of N,N-dimethylformamide were put into a
reactor provided with a stirrer and heater in N.sub.2 atmosphere,
the mixture was reacted at 130.degree. C. for 12 hours, and DMF was
removed by reducing pressure. The obtained solid material was
dissolved in 200 ml of dichloromethane and liquid-liquid separation
was performed with 100 ml of water three times. The organic layer
was dehydrated with 5 g of magnesium sulfate, and dichloromethane
was removed by reducing pressure, whereby an intermediate product A
(nitro material) was obtained.
[0242] Then, the intermediate product A (0.02 mol), 5% palladium on
carbon (Pd/C) (1 g), and 200 ml of ethanol/dichloromethane (70/30)
were put into a reactor provided with a stirrer, hydrogen
substitution was performed five times, the reaction was performed
in a state in which hydrogen was supplied at 25.degree. C. all
times, and the reaction was ended when the hydrogen reduction no
longer occurs. The Pd/C was retrieved, and the mixed solvent was
removed, whereby an intermediate product B (amine material) was
obtained.
[0243] Then, the intermediate product B (0.015 mol), imidazole (0.2
mol), carbon disulfide (0.2 mol), and 150 ml of acetonitrile were
put into a reactor provided with a stirrer and a heater in N.sub.2
atmosphere. The temperature of the reaction solution was set to
100.degree. C., and the reaction was performed for 15 hours. The
solid precipitated after the reaction was retrieved by filtration,
and the resultant product was washed, whereby an intermediate
product C (thiourea material) was obtained.
[0244] Then, the intermediate product C (0.01 mol), 30% NaOH (0.04
mol), benzyltriethylammonium chloride (0.002 mol), 200 ml of
chloroform, and 6.6 ml of methanol were put into a reactor provided
with a stirrer and a heater and the mixture was stirred. After
10.5% aqueous solution of hypochlorite (0.08 mol) was slowly added
dropwise thereto and stirred for 1 hour, a liquid-liquid separation
was performed three times with pure water.
[0245] The obtained chloroform solution was dehydrated with
magnesium sulfate and concentrated, and the concentrated product
was washed with hexane two times, whereby an intended compound was
obtained. The structure was confirmed by NMR and IR. By the above
reaction, a compound 4 was synthesized.
Example 1
[0246] 1. Preparation of Saturated Polyester Resin
[0247] --Step (A)--
[0248] 4.7 tons of high-purity terephthalic acid and 1.8 tons of
ethylene glycol were mixed over 90 minutes to form slurry, and the
slurry was continuously supplied to a first esterification reaction
tank at a flow rate of 3800 kg/h. Subsequently, an ethylene glycol
solution of a citric acid chelated titanium complex (VERTEC AC-420,
manufactured by Johnson Matthey Plc.) having Ti metal coordinated
with citric acid was continuously supplied, to a first
esterification reaction tank and a reaction was performed at a
temperature inside the reaction tank of 250.degree. C. and for an
average retention time of about 4.4 hours with stirring, thereby
obtaining an oligomer. At this time, the citric acid chelated
titanium complex was continuously added such that the addition
amount of Ti was 9 ppm in terms of elements. At this time, the acid
value of the oligomer thus obtained was 500 eq/ton.
[0249] The obtained oligomer was transferred to a second
esterification reaction tank, and with stirring, the reaction
product was allowed to react at a temperature inside the reaction
tank of 250.degree. C. for an average retention time of 1.2 hours
to obtain an oligomer having an acid value of 180 eq/ton. The
inside of the second esterification reaction tank was divided into
three zones ranging a first zone to a third zone. At a second zone,
an ethylene glycol solution of magnesium acetate was continuously
supplied in a manner that the addition amount of Mg was 75 ppm in
terms of elements. After that, at a third zone, an ethylene glycol
solution of trimethyl phosphate was continuously supplied in a
manner that the addition amount of P was 65 ppm in terms of
elements. Further, the ethylene glycol solution of trimethyl
phosphate was prepared by adding a trimethyl phosphate solution at
25.degree. C. to an ethylene glycol solution at 25.degree. C.,
followed by stirring at 25.degree. C. for 2 hours (content of
phosphorous compounds in the solution: 3.8% by mass).
[0250] Thus, an esterification reaction product was obtained.
[0251] --Step (B)--
[0252] The esterification reaction product obtained in the step (A)
was continuously supplied to a first polycondensation reaction
tank. Subsequently, polycondensation (transesterification reaction)
was performed with stirring the esterification reaction product at
a reaction temperature of 270.degree. C. and a pressure inside the
reaction tank of 20 torr (2.67.times.10.sup.-3 MPa) for an average
retention time of about 1.8 hours.
[0253] Then, the obtained reaction product was transferred from the
first polycondensation reaction tank to a second polycondensation
reaction tank, and in this reaction tank, a reaction
(transesterification reaction) was performed with stirring under
the conditions of a temperature inside the reaction tank of
276.degree. C. and a pressure inside the reaction tank of 5 torr
(6.67.times.10.sup.-4 MPa) for a retention time of about 1.2
hours.
[0254] Subsequently, the reaction product obtained by the
transesterification reaction was transferred from the second
polycondensation reaction tank to a third polycondensation reaction
tank, and in this reaction tank, a reaction (transesterification
reaction) was performed with stirring under the conditions of a
temperature inside the reaction tank of 276.degree. C. and a
pressure inside the reaction tank of 1.5 torr (2.0'10.sup.-4 MPa)
for a retention time of 1.5 hours to obtain a reaction product
(polyethylene terephthalate (PET)) having a carboxylic acid value
of 22 eq/ton and an IV (intrinsic viscosity) of 0.65 dl/g.
[0255] Furthermore, the obtained PET was subjected to a heat
treatment (solid-phase polymerization) for 24 hours at 205.degree.
C. under a reduced pressure of 50 Pa using a rotary vacuum
polymerizer. Moreover, by increasing the solid-phase polymerization
time, IV is easily increased and AV is easily reduced, and by
increasing the solid-phase polymerization temperature, the AV is
easily increased and the IV is easily reduced.
[0256] Thereafter, nitrogen gas of 25.degree. C. is flowed into the
vacuum polymerizer, and a pellet was cooled to 25.degree. C.,
whereby PET having a carboxylic acid value of 15 eq/ton and an IV
of 0.78 dl/g was obtained.
[0257] 2. Fabrication of Polyester Film and Evaluation
[0258] --Extrusion-Molding (Synthesis Step/Film Forming Step)--
[0259] The obtained PET was put into a hopper of double-screw
kneading extruder having a diameter 50 mm using a main feeder, and
the compound 1 of the present invention was put into a subfeeder,
and melting and extrusion were performed at 280.degree. C. The
extruded melt was passed through a gear pump and a filter (pore
diameter of 20 .mu.m), and extruded from a die to a cooling roll at
20.degree. C., whereby an amorphous sheet was obtained. Moreover,
the extruded melt was adhered to the cooling roll using an
electrostatic application method.
[0260] --Stretching (Biaxial Stretching Step)--
[0261] An unstretched film which was extruded onto the cooling roll
and solidified was subjected to sequential biaxial stretching by
the following method, whereby a polyester film having a thickness
of 175 .mu.m was obtained.
[0262] <Stretching Method>
[0263] (a) Longitudinal Stretching
[0264] The unstretched film is passed through between two pairs of
nip rolls having different peripheral speed, and by this, the
unstretched film was stretched in the longitudinal direction
(transport direction). Moreover, the stretching was performed at a
preheating temperature of 90.degree. C., a stretching temperature
of 90.degree. C., a stretching ratio of 3.5 times, and a stretching
speed of 3,000%/sec.
[0265] (b) Transverse Stretching
[0266] The longitudinally stretched film was transversely stretched
under the following conditions using a tenter.
[0267] <Conditions>
[0268] Preheating temperature: 100.degree. C.
[0269] Stretching temperature: 110.degree. C.
[0270] Stretching ratio: 4.2 times
[0271] Stretching speed: 70%/sec
[0272] --Heat Fixing and Thermal Relaxation--
[0273] Subsequently, the stretched film after finishing the
longitudinal stretching and transverse stretching was heat-fixed
under the following conditions. Furthermore, after heat fixing, the
tenter width was shorten and thermal relaxation was performed under
the following conditions.
[0274] <Heat Fixing Conditions>
[0275] Heat fixing temperature: 198.degree. C.
[0276] Heat fixing time: 2 seconds
[0277] <Thermal Relaxation Conditions>
[0278] Thermal relaxation temperature: 195.degree. C.
[0279] Thermal relaxation ratio: 5%
[0280] --Winding--
[0281] After the heat fixing and the thermal relaxation, both ends
of the polyester film were trimmed by 10 cm. Thereafter, after
knurling 10 mm width of both ends, the polyester film was wound up
at a tension of 25 kg/m. Moreover, the width was 1.5 m, and the
winding length was 2,000 m.
[0282] In the above manner, the polyester film of Example 1 was
fabricated. The obtained sample film has a good surface state in
which there is no pit or wrinkle.
[0283] --Process Evaluation--
[0284] (Increase in Viscosity)
[0285] Sensory evaluation of IV of the film was performed, and the
increase in viscosity was evaluated based on the following
criteria. The obtained results are shown in Table 1 below.
[0286] <Criteria>
[0287] B: IV (after extrusion)-IV' (before extrusion).ltoreq.1.0
dl/g.
[0288] D: 1.0 dl/g<IV (after extrusion)-IV' (before
extrusion).
[0289] (Gas)
[0290] Sensory evaluation of the smoke and the smell generated from
a die of a double-screw extruder was performed, and the
volatilization was evaluated based on the following criteria. The
obtained results are shown in Table 1 below.
[0291] <Criteria>
[0292] B: There was no occurrence of smoke and smell.
[0293] C: There was no occurrence of smoke but there was occurrence
of smell.
[0294] D: There was occurrence of smoke and smell.
[0295] --Performance of Polyester Film--
[0296] (Wet Heat Resistance (PCT Test))
[0297] Hydrolysis resistance was evaluated by a half-life period of
a retention rate of tensile elongation at break. The half-life
period of a retention rate of tensile elongation at break was
evaluated by subjecting the polyester film obtained in Example 1 to
a storage treatment (heat treatment) under the conditions of
120.degree. C. and relative humidity of 100% and measuring the
storage time when tensile elongation at break (%) shown by the
polyester film after storage becomes 50% of tensile elongation at
break (%) shown by the polyester film before storage. The obtained
results are shown in Table 1 below.
[0298] B: The half-life period of tensile elongation at break was
160 hours or greater
[0299] C: The half-life period of tensile elongation at break was
130 hours or greater and less than 60 hours
[0300] D: The half-life period of tensile elongation at break was
less than 130 hours.
[0301] It shows that as the half-life period of a retention rate of
tensile elongation at break is longer, the hydrolysis resistance of
the polyester film is excellent.
[0302] That is, in the polyester film of the present invention, the
half-life period of tensile elongation at break before and after
the storage treatment under the conditions of 120.degree. C. and
relative humidity of 100% is preferably 130 hours or greater, and
more preferably 160 hours or greater.
[0303] (Volatile Component)
[0304] For the obtained polyester film, the amount of volatile
components in the film based on the following criteria was measured
by gas chromatography (trade name P&T-GC/MS, manufactured by
JASCO Corporation), and evaluation was performed according to the
following criteria. The obtained results are shown in Table 1
below.
[0305] <Conditions>
[0306] The obtained polyester film was heated at 280.degree. C. for
10 minutes, and generated gas was detected.
[0307] <Criteria>
[0308] B: A compound derived from carbodiimide was under the
detection limit.
[0309] C: An isocyanate compound derived from carbodiimide was
under the detection limit.
[0310] D: An isocyanate compound derived from carbodiimide was
detected.
[0311] (Film Thickness Uniformity)
[0312] The variation in the film thickness of polyester film when
film formation was continuously performed for 4 hours was
evaluated. The obtained results are shown in Table 1 below.
[0313] A: The variation in the film thickness is 5% or less.
[0314] B: The variation in the film thickness is greater than 5%
and 10% or less.
[0315] C: The variation in the film thickness is greater than 10%
and 15% or less.
[0316] D: The variation in the film thickness is greater than
15%.
[0317] 3. Fabrication of Back Sheet for Solar Cell Module
[0318] A back sheet for a solar cell module was fabricated, using
the polyester film fabricated in Example 1.
[0319] First, on one surface of the polyester film fabricated in
Example 1, the following (i) reflective layer and (ii) readily
adhesive layer were applied in this order by coating.
[0320] (i) Reflective Layer (Colored Layer)
[0321] All the components having the following composition were
mixed and subjected to a dispersion treatment for 1 hour with a
dyno-mill disperser, thereby preparing a pigment dispersion.
[0322] <Formulation of Pigment Dispersion>
TABLE-US-00001 Titanium dioxide 39.9 parts (TIPAQUE R-780-2,
manufactured by Ishihara Sangyo Kaisha, Ltd., 100% by mass of solid
content) Polyvinyl alcohol 8.0 parts (PVA-105, manufactured by
Kuraray Co., Ltd., 10% of solid content) Surfactant 0.5 parts
(DEMOL EP, manufactured by Kao Corp., 25% of solid content)
Distilled water 51.6 parts
[0323] Then, using the obtained pigment dispersion, the components
having the following composition were mixed to prepare a coating
liquid for forming a reflective layer.
[0324] <Formulation of Coating Liquid for Forming Reflective
Layer>
TABLE-US-00002 Pigment dispersion above 71.4 parts Polyacrylic
resin water dispersion 17.1 parts (binder: JURYMER ET410,
manufactured by Nihon Junyaku Co., Ltd., 30% by mass of solid
content) Polyoxyalkylene alkyl ether 2.7 parts (NAROACTY CL95,
manufactured by Sanyo Chemical Industries, Ltd., 1% by mass of
solid content) Oxazoline compound (cross-linking agent) 1.8 parts
(EPOCROS WS-700, manufactured by NIPPON SHOKUBAI Co., Ltd., 25% by
mass of solid content) Distilled water 7.0 parts
[0325] The coating liquid for forming a reflective layer obtained
above was coated on the polyester film of Example 1 by a bar
coater, and dried at 180.degree. C. for 1 minute, thereby forming a
(i) reflective layer (white layer) having a titanium dioxide
coating amount of 6.5 g/m.sup.2.
[0326] (ii) Readily Adhesive Layer
[0327] All of the components with the following composition were
mixed to prepare a coating liquid for a readily adhesive layer. The
coating liquid was coated to a binder coating amount of binder of
0.09 g/m.sup.2 onto the (i) reflective layer, and then dried at
180.degree. C. for 1 minute to form (ii) a readily adhesive
layer.
[0328] <Composition of Coating Liquid for Forming Readily
Adhesive Layer>
TABLE-US-00003 Polyolefin resin water dispersion 5.2 parts
(carboxylic-containing binder: CHEMIPEARL S75N, manufactured by
Mitsui chemicals, Inc., 24% by mass of solid content)
Polyoxyalkylene alkyl ether 7.8 parts (NAROACTY CL95, manufactured
by Sanyo Chemical Industries, Ltd., 1% by mass of solid content)
Oxazoline compound 0.8 parts (EPOCROS WS-700, manufactured by
NIPPON SHOKUBAI Co., Ltd., 25% by mass of solid content) Silica
fine particle water dispersion 2.9 parts (AEROSIL OX-50,
manufactured by Nippon Aerosil Co., Ltd., 10% by mass of solid
content) Distilled water 83.3 parts
[0329] Next, on the surface side opposite to the side having (i)
the reflective layer and (ii) the readily adhesive layer of the
polyester film formed thereon, the following (iii) undercoat layer,
(iv) barrier layer, and (v) antifouling layer were applied by
coating successively from the polyester film side.
[0330] (iii) Undercoat Layer
[0331] All of the components with the following composition were
mixed to prepare a coating liquid for forming an undercoat layer.
This coating liquid was coated on the polyester film and dried at
180.degree. C. for one minute to form an undercoat layer (dried
coating amount: about 0.1 g/m.sup.2).
[0332] <Composition of Coating Liquid for Forming Undercoat
Layer>
TABLE-US-00004 Polyester resin 1.7 parts (VYLONAL MD-1200,
manufactured by TOYOBO Co., Ltd., 17% by mass of solid content)
Polyester resin 3.8 parts (sulfonic acid-containing binder:
PESRESIN A-520, manufactured by TAKAMATSU OIL&FAT Co., Ltd.,
30% by mass of solid content) Polyoxyalkylene alkyl ether 1.5 parts
(NAROACTY CL95, manufactured by Sanyo Chemical Industries, Ltd., 1%
by mass of solid content) Carbodiimide compound 1.3 parts
(CARBODILITE V-02-L2, manufactured by Nisshinbo Industries, Inc.,
10% by mass of solid content) Distilled water 91.7 parts
[0333] (iv) Barrier Layer
[0334] Subsequently, on the surface of thus formed undercoat layer,
an 800 angstroms thick vacuum deposition film of silicon oxide was
formed under the following vacuum deposition conditions. The film
served as a barrier layer.
[0335] <Vacuum Deposition Conditions>
[0336] Reactive gas mixing ratio (unit:slm): hexamethyl
disiloxane/oxygen gas/helium=1/10/10
[0337] Vacuum degree inside vacuum chamber: 5.0.times.10.sup.-6
mbar
[0338] Vacuum degree inside deposition chamber: 6.0.times.10.sup.-2
mbar
[0339] Electric power supplied to cooling and electrode drums: 20
kW
[0340] Film conveying speed: 80 m/minute
[0341] (v) Antifouling Layer
[0342] As shown below, coating liquids for forming a first
antifouling layer and a second antifouling layer were prepared. The
coating liquid for forming the first antifouling layer and the
coating liquid for forming the second antifouling layer were coated
in this order on the barrier layer, so that an antifouling layer
having a bi-layer structure was applied by coating.
[0343] <First Antifouling Layer>
[0344] --Preparation of Coating Liquid for Forming First
Antifouling Layer--
[0345] The components with the following composition were mixed to
prepare a coating liquid for forming the first antifouling
layer.
[0346] <Composition of Coating Liquid>
TABLE-US-00005 CERANATE WSA1070 (manufactured by DIC Corp.) 45.9
parts Oxazoline compound (cross-linking agent) 7.7 parts (EPOCROS
WS-700, manufactured by NIPPON SHOKUBAI Co., Ltd., 25% by mass of
solid content) Polyoxyalkylene alkyl ether 2.0 parts (NAROACTY
CL95, manufactured by Sanyo Chemical Industries, Ltd., 1% by mass
of solid content) Pigment dispersion used for the reflective layer
33.0 parts Distilled water 11.4 parts
[0347] --Formation of First Antifouling Layer--
[0348] The obtained coating liquid was coated on the barrier layer
to a binder coating amount of 3.0 g/m.sup.2, and dried at
180.degree. C. for 1 minute to form the first antifouling
layer.
[0349] --Preparation of Coating Liquid for Forming Second
Antifouling Layer--
[0350] The components with the following composition were mixed to
prepare a coating liquid for forming the second antifouling
layer.
[0351] <Composition of Coating Liquid>
TABLE-US-00006 Obbligato (fluorobinder, manufactured by AGC
Coat-tech) 45.9 parts Oxazoline compound 7.7 parts (EPOCROS WS-700,
manufactured by NIPPON SHOKUBAI Co., Ltd., 25% by mass of solid
content) Polyoxyalkylene alkyl ether 2.0 parts (NAROACTY CL95,
manufactured by Sanyo Chemical Industries, Ltd., 1% by mass of
solid content) Pigment dispersion used for the reflective layer
33.0 parts Distilled water 11.4 parts
[0352] --Formation of Second Antifouling Layer--
[0353] The obtained coating liquid for forming the second
antifouling layer was coated on the first antifouling layer formed
on the barrier layer to a binder coating amount of 2.0 g/m2, and
dried at 180.degree. C. for 1 minute to form the second antifouling
layer.
[0354] As described above, the back sheet for a solar cell module
of Example 1, which has a reflective layer and readily adhesive
layer on one side of the polyester film, and has an undercoat
layer, a barrier layer, and an antifouling layer on the other side,
was fabricated.
Examples 2 to 8 and Comparative Examples 1 to 10
[0355] In the same manner as in Example 1 except for using the
materials described in the following Table 1, a polyester film of
each of Examples and Comparative Examples was produced.
[0356] In the same manner as in Example 1 except for using the
obtained polyester film of each of Examples and Comparative
Examples, aback sheet for a solar cell module of each of Examples
and Comparative Examples was fabricated.
[0357] In each of Examples and Comparative Examples, the results of
evaluation performed in the same manner as in Example 1 are shown
in Table 1 below.
TABLE-US-00007 TABLE 1 Carbodiimide Amount [with respect to 100
Production adaptibility Polyester film performance parts by mass
Increase in Gas Wet heat Volatile Film thickness Type of polyester]
viscosity volatilization resistance component uniformity
Comparative Example 1 Monocarbodiimide 0.4 parts by mass B D C D B
Comparative Example 2 Polycarbodiimide 0.4 parts by mass B D C D B
Comparative Example 3 Polycarbodiimide 1.0 parts by mass B D B D B
Comparative Example 4 Cyclic carbodiimide (1) 0.4 parts by mass D B
C B C Comparative Example 5 Cyclic carbodiimide (1) 1.0 parts by
mass D C B C D Comparative Example 6 Cyclic carbodiimide (2) 0.4
parts by mass D B C B D Comparative Example 7 Cyclic carbodiimide
(2) 1.0 parts by mass D B B B D Comparative Example 8 Cyclic
carbodiimide (3) 0.4 parts by mass D B B B C Comparative Example 9
Cyclic carbodiimide (4) 0.4 parts by mass D B B B C Comparative
Example 10 Cyclic carbodiimide (5) 0.4 parts by mass D B B B C
Example 1 Compound 1 of the 0.4 parts by mass B B B B B present
invention Example 2 Compound 1 of the 1.0 parts by mass B B B B B
present invention Example 3 Compound 1 of the 2.0 parts by mass B C
B C B present invention Example 4 Compound 2 of the 0.4 parts by
mass B B B B B present invention Example 5 Compound 2 of the 1.0
parts by mass B B B B B present invention Example 6 Compound 2 of
the 2.0 parts by mass B B B B B present invention Example 7
Compound 3 of the 1.0 parts by mass B C B C B present invention
Example 8 Compound 4 of the 1.0 parts by mass B B B B B present
invention
[0358] From the above Table 1, when using cyclic carbodiimide
compounds 1 to 4 which are represented by Formula (O-1) or (O-2) of
the present invention used in each Example, it was possible to
suppress increase in viscosity during the film production and
suppress generation of isocyanate gas, and the obtained polyester
film of each Example was excellent in hydrolysis resistance, did
not contain isocyanate having a low molecular weight in the film,
did not increase viscosity, and was good in the film thickness
uniformity.
[0359] Moreover, the present invention is not limited to exhibit
the following effects, and the polyester film of each Example was
also good in wet heat resistance.
[0360] In contrast, in the polyester film of Comparative Examples 1
to 3 using monocarbodiimide or polycarbodiimide having a non-cyclic
structure, isocyanate was generated during the film production, and
a volatile component was included in the film.
[0361] In the polyester film of Comparative Example 4 using a small
amount of cyclic carbodiimide (1) of a monocycle which does not
have a specific functional group at an ortho-position of an arylene
group, increase in viscosity was large during the film production,
and the film production stability was poor.
[0362] In the polyester film of Comparative Example 5 using cyclic
carbodiimide (1) of a monocycle which does not have a specific
functional group at an ortho-position of an arylene group, increase
in viscosity occurred during the film production, and the film
thickness uniformity of the film was poor.
[0363] In the polyester films of Comparative Examples 6 and 7 using
cyclic carbodiimide (2) of a bicycle which does not have a specific
functional group at an ortho-position of an arylene group, increase
in viscosity occurred large during the film production, and the
film thickness uniformity of the film was poor.
[0364] In the polyester film of Comparative Example 8 using cyclic
carbodiimide (3) of a cycle which has, at a meta-position, a
specific functional group at an ortho-position of an arylene group,
increase in viscosity was large during the film production, and the
film production stability was poor.
[0365] In the polyester film of Comparative Example 9 using cyclic
carbodiimide (4) of a cycle which has, at a meta-position, a
specific functional group at an ortho-position of an arylene group,
increase in viscosity was large during the film production, and the
film production stability was poor.
[0366] In the polyester film of Comparative Example 10 using cyclic
carbodiimide (5) of a cycle which has, at a meta-position, a
specific functional group at an ortho-position of an arylene group,
increase in viscosity was large during the film production, and the
film production stability was poor.
[0367] [Fabrication of Solar Cell Module]
[0368] The back sheet for a solar cell module of each Example
fabricated as described above was bonded to a transparent filler to
form the structure as in FIG. 1 in JP-A-2009-158952, thereby
fabricating a solar cell module.
[0369] At this time, adhesion was made such that the readily
adhesive layer of the back sheet for a solar cell module of each
Example was in contact with the transparent filler in which
photovoltaic cells were embedded.
[0370] It was confirmed that the fabricated solar cell module can
generate power stably over a long period of time.
[0371] While the present invention has been described in detail and
with reference to specific embodiments thereof, it will be apparent
to one skilled in the art that various changes and modifications
can be made therein without departing from the spirit and scope
thereof.
[0372] The present disclosure relates to the subject matter
contained in International Application No. PCT/JP2013/062184, filed
on Apr. 25, 2013; Japanese Application No. 2012-113227, filed on
May 17, 2012; and Japanese Application No. 2012-180258, filed on
Aug. 15, 2012, the contents of which are expressly incorporated
herein by reference in their entirety. All the publications
referred to in the present specification are also expressly
incorporated herein by reference in their entirety.
[0373] The foregoing description of preferred embodiments of the
invention has been presented for purposes of illustration and
description, and is not intended to be exhaustive or to limit the
invention to the precise form disclosed. The description was
selected to best explain the principles of the invention and their
practical application to enable others skilled in the art to best
utilize the invention in various embodiments and various
modifications as are suited to the particular use contemplated. It
is intended that the scope of the invention not be limited by the
specification, but be defined claims set forth below.
* * * * *